US20170094729A1 - Method and Apparatus for Fabricating a Susceptor Coil Assembly Ribbon - Google Patents
Method and Apparatus for Fabricating a Susceptor Coil Assembly Ribbon Download PDFInfo
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- US20170094729A1 US20170094729A1 US14/870,531 US201514870531A US2017094729A1 US 20170094729 A1 US20170094729 A1 US 20170094729A1 US 201514870531 A US201514870531 A US 201514870531A US 2017094729 A1 US2017094729 A1 US 2017094729A1
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- susceptor coil
- section
- susceptor
- coil assemblies
- coil assembly
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
- H01B13/06—Insulating conductors or cables
- H01B13/10—Insulating conductors or cables by longitudinal lapping
- H01B13/103—Insulating conductors or cables by longitudinal lapping combined with pressing of plastic material around the conductors
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
- H05B6/00—Heating by electric, magnetic or electromagnetic fields
- H05B6/02—Induction heating
- H05B6/10—Induction heating apparatus, other than furnaces, for specific applications
- H05B6/105—Induction heating apparatus, other than furnaces, for specific applications using a susceptor
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H49/00—Unwinding or paying-out filamentary material; Supporting, storing or transporting packages from which filamentary material is to be withdrawn or paid-out
- B65H49/18—Methods or apparatus in which packages rotate
- B65H49/20—Package-supporting devices
- B65H49/32—Stands or frameworks
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
- B29C70/32—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core on a rotating mould, former or core
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C71/00—After-treatment of articles without altering their shape; Apparatus therefor
- B29C71/04—After-treatment of articles without altering their shape; Apparatus therefor by wave energy or particle radiation, e.g. for curing or vulcanising preformed articles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H54/00—Winding, coiling, or depositing filamentary material
- B65H54/02—Winding and traversing material on to reels, bobbins, tubes, or like package cores or formers
- B65H54/04—Winding and traversing material on to reels, bobbins, tubes, or like package cores or formers for making packages with closely-wound convolutions
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H54/00—Winding, coiling, or depositing filamentary material
- B65H54/02—Winding and traversing material on to reels, bobbins, tubes, or like package cores or formers
- B65H54/22—Automatic winding machines, i.e. machines with servicing units for automatically performing end-finding, interconnecting of successive lengths of material, controlling and fault-detecting of the running material and replacing or removing of full or empty cores
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H57/00—Guides for filamentary materials; Supports therefor
- B65H57/12—Tubes
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H57/00—Guides for filamentary materials; Supports therefor
- B65H57/16—Guides for filamentary materials; Supports therefor formed to maintain a plurality of filaments in spaced relation
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H59/00—Adjusting or controlling tension in filamentary material, e.g. for preventing snarling; Applications of tension indicators
- B65H59/02—Adjusting or controlling tension in filamentary material, e.g. for preventing snarling; Applications of tension indicators by regulating delivery of material from supply package
- B65H59/04—Adjusting or controlling tension in filamentary material, e.g. for preventing snarling; Applications of tension indicators by regulating delivery of material from supply package by devices acting on package or support
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H59/00—Adjusting or controlling tension in filamentary material, e.g. for preventing snarling; Applications of tension indicators
- B65H59/38—Adjusting or controlling tension in filamentary material, e.g. for preventing snarling; Applications of tension indicators by regulating speed of driving mechanism of unwinding, paying-out, forwarding, winding, or depositing devices, e.g. automatically in response to variations in tension
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H59/00—Adjusting or controlling tension in filamentary material, e.g. for preventing snarling; Applications of tension indicators
- B65H59/38—Adjusting or controlling tension in filamentary material, e.g. for preventing snarling; Applications of tension indicators by regulating speed of driving mechanism of unwinding, paying-out, forwarding, winding, or depositing devices, e.g. automatically in response to variations in tension
- B65H59/384—Adjusting or controlling tension in filamentary material, e.g. for preventing snarling; Applications of tension indicators by regulating speed of driving mechanism of unwinding, paying-out, forwarding, winding, or depositing devices, e.g. automatically in response to variations in tension using electronic means
- B65H59/385—Regulating winding speed
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H61/00—Applications of devices for metering predetermined lengths of running material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C33/00—Moulds or cores; Details thereof or accessories therefor
- B29C33/02—Moulds or cores; Details thereof or accessories therefor with incorporated heating or cooling means
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
- B29L2031/3076—Aircrafts
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B64—AIRCRAFT; AVIATION; COSMONAUTICS
- B64C—AEROPLANES; HELICOPTERS
- B64C1/00—Fuselages; Constructional features common to fuselages, wings, stabilising surfaces or the like
- B64C2001/0054—Fuselage structures substantially made from particular materials
- B64C2001/0072—Fuselage structures substantially made from particular materials from composite materials
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B64—AIRCRAFT; AVIATION; COSMONAUTICS
- B64F—GROUND OR AIRCRAFT-CARRIER-DECK INSTALLATIONS SPECIALLY ADAPTED FOR USE IN CONNECTION WITH AIRCRAFT; DESIGNING, MANUFACTURING, ASSEMBLING, CLEANING, MAINTAINING OR REPAIRING AIRCRAFT, NOT OTHERWISE PROVIDED FOR; HANDLING, TRANSPORTING, TESTING OR INSPECTING AIRCRAFT COMPONENTS, NOT OTHERWISE PROVIDED FOR
- B64F5/00—Designing, manufacturing, assembling, cleaning, maintaining or repairing aircraft, not otherwise provided for; Handling, transporting, testing or inspecting aircraft components, not otherwise provided for
- B64F5/40—Maintaining or repairing aircraft
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H2301/00—Handling processes for sheets or webs
- B65H2301/40—Type of handling process
- B65H2301/41—Winding, unwinding
- B65H2301/414—Winding
- B65H2301/4148—Winding slitting
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H2403/00—Power transmission; Driving means
- B65H2403/70—Clutches; Couplings
- B65H2403/72—Clutches, brakes, e.g. one-way clutch +F204
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H2701/00—Handled material; Storage means
- B65H2701/30—Handled filamentary material
- B65H2701/36—Wires
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/08—Flat or ribbon cables
- H01B7/0838—Parallel wires, sandwiched between two insulating layers
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T50/00—Aeronautics or air transport
- Y02T50/40—Weight reduction
Definitions
- the present disclosure relates generally to susceptors for use with heating blankets. More particularly, the present disclosure relates to methods and apparatus for fabricating a susceptor coil assembly ribbon wherein the ribbon comprises a plurality of susceptor coil assemblies.
- a composite part may be bonded or cured in an oven or an autoclave where heat is applied to the part while supported on a cure tool that maintains the shape of the part during the curing process.
- Techniques have been developed for curing composite parts without the need for an oven or autoclave. However, these techniques have been limited to curing relatively small, simple parts and/or require relatively complicated and/or expensive tooling.
- curing of relatively small composite parts has been achieved using induction heating equipment employing ferromagnetic susceptors that produce a maximum, constant temperature when inductively heated. For example, heating blankets using inductively heated susceptors have been used to cure relatively small areas of a composite rework patch applied to a structure such as an aircraft skin.
- the blankets are constructed by threading springs of susceptor wire onto a length of a conductor wire that is designed for carrying high frequency current, commonly referred to in the art as a Litz wire.
- a Litz wire When threading the susceptor wire onto the conductor wire, it is generally desired to orient the susceptor wire as near to perpendicular as possible to the direction of current flow in the Litz wire. A near perpendicular orientation is desired so as to maximize the induced magnetic fields into the susceptor wire which creates heat by virtue of eddy currents created by the wire.
- the susceptor can be oriented along the Litz wire in order to capitalize on a high density of susceptor per unit length of the Litz wire and keep the susceptor wire in the region of highest magnetic field strength (i.e., as close to orthogonal to the direction of current flow within the Litz wire).
- This threaded spring configuration has been shown to produce suitable results for certain heating blanket applications, but also has demonstrated certain limitations.
- a large amount of Litz wire is typically required to carry the appropriate amount of current for large heating blankets.
- a large amount of Litz wire is typically also required to maintain an applied voltage within certain safety levels, and also to produce the required amount of heat. Therefore, the spring threaded configurations do not lend themselves to providing a practical heating blanket for large heating or curing applications.
- susceptor springs were not cost effective for large sized heating blankets.
- an apparatus 10 for fabricating a susceptor coil assembly ribbon 30 comprising a tensioning section 100 that provides a predetermined amount of tension to a plurality of susceptor coil assemblies 20 , a collimating section 200 that receives the plurality of susceptor coil assemblies 20 from the tensioning section 100 and aligns the plurality of susceptor coil assemblies 20 and an impaling section 300 that receives the plurality of susceptor coil assemblies 20 aligned by the collimating section 200 and impales the plurality of susceptor coil assemblies 20 into a matrix material 320 so as to fabricate a susceptor coil assembly ribbon 30 .
- the apparatus 10 further comprises a take up section 400 for receiving the susceptor coil assembly ribbon 30 from the impaling section 300 , the take up section 400 winding the susceptor coil assembly ribbon 30 onto a take up spool 450 .
- the take up section 400 comprises a programmable drive system 460 that is programmable to operate a take up motor 470 , preferably a smart motor 475 .
- the take up motor 470 is operable to pull the plurality of susceptor coil assemblies 20 from the tensioning section 100 through the impaling section 300 .
- the tensioning section 100 comprises a plurality of spools 130 wherein each of the plurality of spools 130 is wound with a length of one of the plurality of susceptor coil assemblies 20 .
- at least one of the plurality of spools 130 is mounted to an adjustable drag member 150 .
- the adjustable drag member 150 comprises a slip-clutch mechanism 160 .
- the slip-clutch mechanism 160 allows the length of the at least one of the plurality of susceptor coil assemblies wound on the spool to slip as the plurality of susceptor coil assemblies 30 are pulled from the tensioning section 100 towards the impaling section 300 .
- the collimating section 200 comprises a multi-grooved aligning member 215 .
- the aligning member 215 comprising a plurality of grooves 240 that are configured to align the plurality of susceptor coil assemblies 120 as the plurality of susceptor coil assemblies 120 are pulled from the tensioning section 100 and into the impaling section 300 .
- the impaling section 300 comprises a plurality of pinch rollers 340 that receive the plurality of susceptor coil assemblies 20 aligned by the collimating section 200 and that impales the plurality of susceptor coil assemblies 20 into the matrix material 320 so as to fabricate the susceptor coil assembly ribbon 30 .
- the plurality of pinch rollers 340 impales the plurality of susceptor coil assemblies 20 into the matrix material 320 so as to fabricate the susceptor coil assembly ribbon 30 .
- the susceptor coil assembly ribbon 30 comprises a pre-determined depth 35 .
- the apparatus 10 further comprises at least a first matrix material source 324 . In another exemplary arrangement, the apparatus 10 further comprises at least a first matrix material source 324 and a second matrix material source 328 .
- the impaling section 300 that receives the plurality of susceptor coil assemblies 20 aligned by the collimating section 200 , impales the plurality of susceptor coil assemblies 20 into at least one layer of the matrix material 320 so as to fabricate a susceptor coil assembly ribbon 30 .
- the apparatus comprises a slitting section 500 that receives the susceptor coil assembly ribbon 30 from the impaling section 300 and slits the susceptor coil assembly ribbon 30 to a desired susceptor coil assembly width 40 .
- a method for fabricating a susceptor coil assembly ribbon 30 comprising the steps of pulling a plurality of susceptor coil assemblies 20 from a tensioning section 100 towards a collimating section 300 .
- the method includes the steps of collimating the plurality of susceptor coil assemblies 20 as the plurality of susceptor coil assemblies 20 are pulled from the tensioning section 100 towards a collimating section 200 so as to align the plurality of susceptor coil assemblies 20 and impaling the plurality of susceptor coil assemblies 20 into a matrix material 320 so as to fabricate a susceptor coil assembly ribbon 30 .
- the method further comprises the step of receiving the susceptor coil assembly ribbon 30 from the impaling section 300 by a take up section 400 , the take up section 400 comprising a take up spool 450 and winding the susceptor coil assembly ribbon 30 onto the take up spool 450 .
- the method further comprises the step of utilizing a programmable drive system 460 to pull the plurality of susceptor coil assemblies 20 from the tensioning section 100 through the impaling section 300 , the programmable drive system 460 is programmable to operate a take up motor 470 .
- the method further comprises the step of utilizing a multi-grooved aligning member 215 comprising a plurality of grooves 240 to align the plurality of susceptor coil assemblies 20 as the plurality of susceptor coil assemblies 20 are pulled from the tensioning section 100 and into the impaling section 300 .
- the method further comprises the step of maintaining a desired tension in the plurality of susceptor coil assemblies 20 as the plurality of susceptor coil assemblies 20 are pulled from the tensioning section 100 towards the collimating section 200 .
- the step of impaling the plurality of susceptor coil assemblies 20 into a matrix material 320 so as to fabricate a susceptor coil assembly ribbon 30 comprises the step of impaling the plurality of susceptor coil assemblies 20 into at least one layer of the matrix material 320 so as to fabricate a susceptor coil assembly ribbon 30 .
- the method further comprises the step of winding the susceptor coil assembly ribbon 30 onto a take up spool 450 .
- the method further comprises the step of slitting the susceptor coil assembly ribbon 30 to a desired susceptor coil assembly ribbon width 40 .
- FIG. 1 is a diagrammatic representation of a functional block diagram of a apparatus for fabricating a susceptor coil assembly ribbon according to disclosed embodiments;
- FIG. 2 is a diagrammatic representation of a susceptor coil assembly that may be utilized by an apparatus to fabricate a susceptor coil assembly ribbon, such as the apparatus represented by the functional block diagram of FIG. 1 ;
- FIG. 3 is a diagrammatic representation of an example computing device, according to one embodiment
- FIG. 4 is a diagrammatic representation of an apparatus for fabricating a susceptor coil assembly ribbon according to disclosed embodiments
- FIG. 5 a diagrammatic representation of a tensioning section of the apparatus of FIG. 4 ;
- FIG. 6 is another diagrammatic representation of a tensioning section of the apparatus of FIG. 4 ;
- FIG. 7 is a diagrammatic representation of a slip clutch mechanism that may be used with the tensioning section illustrated in FIGS. 5 and 6 [TW1] [k2] ;
- FIG. 8 is a diagrammatic representation of a portion of the collimating section of an apparatus for fabricating a susceptor coil assembly ribbon according to disclosed embodiments
- FIG. 9 is a diagrammatic representation of a collimating section of an apparatus for fabricating a susceptor coil assembly ribbon according to disclosed embodiments.
- FIG. 10 is a diagrammatic representation of a multi-grooved aligning member of the collimating section illustrated in FIG. 9 ;
- FIG. 11 is a diagrammatic representation of the multi-grooved aligning member housing illustrated in FIG. 10 ;
- FIG. 12 is a diagrammatic representation of rotating multi-grooved aligning member that is configured to operate with the multi-grooved aligning member illustrated in FIG. 10 ;
- FIG. 13 is a diagrammatic representation of an impaling section of an apparatus for fabricating a susceptor coil assembly ribbon according to disclosed embodiments
- FIG. 14A is another diagrammatic representation of an impaling section of an apparatus for fabricating a susceptor coil assembly ribbon according to disclosed embodiments
- FIG. 14B is another diagrammatic representation of an impaling section of an apparatus for fabricating a susceptor coil assembly ribbon according to disclosed embodiments
- FIG. 15 is a diagrammatic representation of an adjusting plate used to adjust the positions of the pinch rollers illustrated in FIG. 14 ;
- FIG. 16 is another diagrammatic representation of an adjusting plate for use with a plurality of pinch rollers as disclosed herein;
- FIG. 17 is another diagrammatic representation of an impaling section as disclosed herein;
- FIG. 18 a diagrammatic representation of a take up section illustrated in FIG. 4 ;
- FIG. 19 a diagrammatic representation of a take up spool of the take up section illustrated in FIG. 18 ;
- FIG. 20 illustrates steps of a method of fabricating a susceptor coil assembly ribbon, such as the susceptor coil assembly ribbon disclosed herein;
- FIG. 21 is a diagrammatic representation of a perspective view of an aircraft that may incorporate one or more composite laminate structures manufactured in accordance with one or more embodiments disclosed herein;
- FIG. 22 is a diagrammatic representation of a flow diagram of aircraft production and service methodology.
- FIG. 23 is a diagrammatic representation of a block diagram of an aircraft.
- FIG. 1 is a diagrammatic representation of a functional block diagram of an apparatus 10 for fabricating a susceptor coil assembly ribbon 30 according to disclosed embodiments.
- the susceptor coil assembly ribbon 30 comprises a plurality of susceptor coil assemblies 20 (i.e., a smart susceptor that is wound or coiled generally perpendicularly along an outer surface of a conductor wire where the wound coils reside perpendicular to a longitudinal axis of the conductor wire e.g., a Litz wire).
- susceptor coil assemblies 20 i.e., a smart susceptor that is wound or coiled generally perpendicularly along an outer surface of a conductor wire where the wound coils reside perpendicular to a longitudinal axis of the conductor wire e.g., a Litz wire.
- corresponding patent disclosure entitled “Method and Apparatus For Fabricating Susceptor Coil Assemblies,” filed simultaneously along with the present disclosure generally describes methods and apparatus for fabricating such suscept
- the disclosed apparatus 10 impales (i.e., imbeds) the plurality of susceptor coil assemblies 20 within a matrix material 320 (e.g., a B-stage silicon rubber) to thereby fabricate the susceptor coil assembly ribbon 30 .
- a matrix material 320 e.g., a B-stage silicon rubber
- FIG. 2 an exemplary susceptor coil assembly 20 is illustrated in FIG. 2 .
- a plurality of such susceptor coil assemblies 20 may be embedded within one or more layers of a matrix material 320 so as to form a susceptor coil assembly ribbon 30 .
- the ribbon 30 may then be slit to a desired ribbon width 40 and then the ribbon 30 may be wound by a take up section 400 .
- the ribbon 30 and its matrix material 320 may then be heated and cured.
- the cured ribbon 30 may then be used in for a range of heating applications, such as a heating blanket for heating composite structures.
- the apparatus 10 for fabricating a susceptor coil assembly ribbon 30 comprises three processing sections: a tensioning section 100 , a collimating section 200 , and an impaling section 300 .
- the apparatus 10 may include a slitting section 500 .
- the slitting section 500 can be operated to slit the fabricated ribbon 30 to a desired ribbon width 40 .
- take up section 400 may be used to wind the ribbon 30 that it receives from either the slitting section 500 or from the impaling section 300 . In one arrangement, the take up section 400 winds the ribbon 30 onto a take up spool 450 .
- One or more of the apparatus sections 100 , 200 , 300 , 400 , and 500 may be operated and/or controlled by way of computing device 725 .
- a programmable drive system 460 is programmable to operate a programmable drive 430 and a take up motor 470 to achieve a desired feed rate of the plurality of susceptor coil assemblies 20 from the tensioning section 100 to the impaling section 300 .
- the take up motor 470 comprises a smart motor 475 such as an induction motor comprising an integral encoder that provides position shaft position feedback to the system software 700 .
- the programmable drive system 460 may be operated and controlled by way of a computing device 725 running the system software 700 .
- the tensioning section 100 , the collimating section 200 , the impaling section 300 , and the take up section 400 may all be operated by way of the computing device 725 wherein the system software 700 may be accessible by way of a graphical user interface 750 (i.e., GUI).
- the system software 700 may comprise a G-code logic system software provided by Moog Animatics.
- the apparatus 10 comprises a programmable drive system 460 that may be operated so as to fabricate a susceptor coil assembly ribbon 30 comprising a plurality of susceptor coil assemblies 20 (such as the susceptor coil assembly 20 illustrated in FIG. 2 ) that are impaled into a matrix material 320 (e.g., one or more layers of matrix material).
- the various sections 100 , 200 , 300 of the apparatus 10 are supported along a portion of a top surface 820 of a base 800 for support of the various components.
- the base 800 of the apparatus 10 is further supported by an apparatus frame 900 .
- the tensioning section 100 comprises a susceptor coil assembly supply 120 for supplying a plurality of susceptor coil assemblies 20 to the collimating section 200 .
- the tensioning section 100 simultaneously provides the plurality of susceptor coil assemblies 20 into the collimating section 200 at a predetermined rate or feed rate.
- the take up section 400 utilizes the programmable drive system 460 to control a take up motor 470 that turns the take up spool 450 in a controlled manner.
- the ribbon 30 (and therefore the plurality of susceptor coil assemblies 20 making up the ribbon 30 ) are pulled from the tensioning section 100 , into the collimating section 200 , and then through the impaling section 300 .
- the programmable drive system 460 is operated and controlled by the system software 700 and whose operating settings may be accessible by way of the graphical user interface 750 .
- the apparatus 10 further includes the collimating section 200 which resides downstream of the tensioning section 100 .
- the collimating section 200 comprises a multi-grooved aligning member 215 that receives the plurality of susceptor coil assemblies 20 from the tensioning section 100 .
- the multi-grooved aligning member 215 aligns the plurality of susceptor coil assemblies 20 as the plurality of assemblies 20 are channeled through a plurality of grooves 240 defined by the multi-grooved aligning member 215 .
- the assemblies 20 enter the impaling section 300 . Aside from receiving the now aligned plurality of susceptor coil assemblies 20 , the impaling section 300 also receives a matrix material 320 .
- a slitting section 500 is positioned downstream of the impaling section 300 and receives the fabricated susceptor coil assembly ribbon 30 from the impaling section 300 .
- the slitting section 500 is operated to slit the ribbon 30 to a desired ribbon width 40 .
- the ribbon 30 comprising a desired or predetermined width 40 may then be provided to the take up section 400 where the ribbon 30 is then wound up on a take up spool 450 .
- the take up section 400 is positioned downstream of the impaling section 300 and receives the fabricated susceptor coil assembly ribbon 30 directly from the impaling section 300 .
- the take up section 400 comprises a take up spool 450 and a programmable drive system 460 .
- the programmable drive system 460 comprises a programmable drive 430 and a take up motor 470 .
- the tensioning section 100 is programmed by way of a graphical user interface 750 provided by a computing device 725 so as to maintain a desired speed of the plurality of susceptor coil assemblies 20 as these coil assemblies 20 are pulled from the tensioning section 100 through the collimating section 200 and towards the impaling section 300 .
- FIG. 3 illustrates a schematic drawing of an example computing device 725 .
- the computing device 725 illustrated in FIG. 3 may represent the computing device 725 for use with the apparatus 10 illustrated in FIG. 1 .
- components illustrated in FIG. 3 may be distributed across multiple computing devices. However, for the sake of example, the components are shown and described as part of one example computing device 725 .
- the computing device 725 may include an interface 727 , a wireless communication component 729 , sensor(s) 731 , data storage 733 , and a processor 735 . Components illustrated in FIG. 3 may be linked together by a communication link 737 .
- the computing device 725 may also include hardware to enable communication between the computing device 725 and another computing device (not shown), such as a server entity.
- the hardware may include transmitters, receivers, and antennas, for example.
- the interface 727 may be configured to allow the computing device 725 to communicate with another computing device (not shown), such as a server or land-based device. Thus, the interface 727 may be configured to receive input data from one or more computing devices, and may also be configured to send output data to the one or more computing devices. In some examples, the interface 727 may also maintain and manage records of data received and sent by the computing device 725 . The interface 727 may also include a receiver and transmitter to receive and send data.
- the wireless communication component 729 may be a communication interface that is configured to facilitate wireless data communication for the computing device 725 according to one or more wireless communication standards.
- the wireless communication component 729 may include a Wi-Fi communication component, or a cellular communication component.
- Other examples are also possible, such as proprietary wireless communication devices.
- the sensor(s) 731 may include one or more sensors, or may represent one or more sensors included within the computing device 725 .
- Example sensors may include one or more encoders, one or more accelerometers, one or more magnetometers, one or more optical sensors, and/or one or more infrared sensors, or any other similar type sensors may be incorporated into the computing device 725 .
- the sensors 731 may more generally include sensors for detecting the position of the susceptor coil assemblies, the feed rates of the coil assemblies and/or the matrix material, the torque characteristics and/or shaft speed of motor 450 , and/or the linear speed of the ribbon 30 and its various components.
- the sensors 731 may also be used to track and monitor how much ribbon 30 has been wound on the take up spool 450 .
- the processor 735 may be implemented, or realized, with a general purpose processor, a content addressable memory, a digital signal processor, an application specific integrated circuit, a field programmable gate array, any suitable programmable logic device, discrete gate or transistor logic, discrete hardware components, or any combination thereof, designed to perform the functions described herein.
- a processor may be realized as a microprocessor, a computing device, a micro-computing device, a state machine, or the like.
- a processor may also be implemented as a combination of computing devices, e.g., a combination of a digital signal processor and a microprocessor, a plurality of microprocessors, one or more microprocessors in conjunction with a digital signal processor core, or any other such configuration.
- the data storage 733 may contain program logic 739 and reference data 741 .
- Reference data 741 is configured to store, maintain, and provide data as needed to support the functionality of the system.
- the reference data 741 may comprise the type of smart susceptor used to fabricate the coil assemblies, the amount of drag provided by the plurality of adjustable drag members 150 , the type of Litz wire used, the turns per unit length of Litz wire, the size of the coil assemblies, the length of the susceptor coil assemblies 20 , and/or other types of operating data.
- Program logic 739 may then comprise machine language instructions or the like that are executable by the processor 735 to carry out various functions described herein.
- the data storage 733 may comprise, for example but without limitation, a non-volatile storage device (non-volatile semiconductor memory, hard disk device, optical disk device, and the like), a random access storage device (for example, SRAM, DRAM), or any other form of storage medium known in the art.
- a non-volatile storage device non-volatile semiconductor memory, hard disk device, optical disk device, and the like
- a random access storage device for example, SRAM, DRAM
- the data storage 733 may be coupled to the processor 735 and configured to store, for example but without limitation, a database, and the like. Additionally, the data storage 733 may represent a dynamically updating database containing a table for updating the database, and the like.
- the data storage 733 may be coupled to the processor 735 such that the processor 735 can read information from and write information to the data storage 733 .
- the processor 735 may access the data storage 733 to access a predetermined tension, a linear speed, a desired motor speed, tensioning section information, impaling section information, slitting section information, take up section information, or other data.
- the processor 735 and data storage 733 may reside in respective application specific integrated circuits (ASICs).
- ASICs application specific integrated circuits
- the data storage 733 may also be integrated into the processor 735 .
- the data storage 733 may comprise a cache memory for storing temporary variables or other intermediate information during execution of instructions to be executed by the processor 735 .
- FIG. 4 is a diagrammatic representation of an apparatus 10 for fabricating a susceptor coil assembly ribbon 30 according to disclosed embodiments, similar in operation to the apparatus 10 illustrated in FIG. 1 .
- the apparatus 10 illustrated in FIG. 4 may be used for fabricating a susceptor coil assembly ribbon 30 .
- the apparatus 10 for fabricating a susceptor coil assembly ribbon 30 comprises three processing sections: a tensioning section 100 , a collimating section 200 , and an impaling section 300 .
- the apparatus 10 may include a slitting section 500 (not shown). The slitting section 500 can be operated to slit the fabricated ribbon 30 to a desired width 40 .
- a take up section 400 may be used to wind the fabricated ribbon 30 that is received from either the slitting section 500 or from the impaling section 300 .
- the take up section 400 winds the ribbon 30 onto a take up spool 450 .
- Each of the apparatus sections 100 , 200 , 300 , 400 , and 500 may be operated and/or controlled by way of computing device 725 as herein described.
- the various sections 100 , 200 , 300 of the apparatus 10 are supported along a top surface 820 of a base 800 portion for support the various components.
- the base 800 of the apparatus 10 is further supported by an apparatus frame 900 .
- the tensioning section 100 comprises a susceptor coil assembly supply 120 .
- susceptor coil assembly supply 120 comprises a plurality of susceptor coil assemblies 20 wound around a plurality of spools 130 .
- each spool 130 is provided with a length of a susceptor coil assembly 20 .
- each susceptor coil assembly 20 within the susceptor coil assembly supply 120 comprises the same type of susceptor coil assembly 20 (i.e., the same type of susceptor wire 22 wrapped around the outer surface 26 of the conductor wire 24 and using the same number of wraps per inch).
- the susceptor coil assembly supply 120 may comprise different types of susceptor coil assemblies 20 (i.e., different types of susceptor wire 22 wrapped around different types of conductor wire 24 , and perhaps using a higher and/or lower number of wraps per inch).
- a layout of an anticipated heating blanket and the heating blanket's heat producing requirements might dictate what type of susceptor coil assemblies 20 are to be provided to the plurality of spools 130 of the tensioning section 100 .
- a layout of an anticipated heating blanket and the heating blanket's heat producing requirements might also dictate how many of the plurality of spools 130 of the tensioning section 100 are used during susceptor coil assembly ribbon 30 fabrication.
- FIG. 5 a diagrammatic representation of a tensioning section 100 of the apparatus of FIG. 4 .
- FIG. 6 is another diagrammatic representation of a tensioning section 100 of the apparatus 10 of FIG. 4 .
- the tensioning section 100 comprises up to fifty (50) or more spools 130 of susceptor coil assemblies 20 that are mounted on a tensioning section frame 102 .
- the tensioning section frame 102 comprises a plurality of vertical mounting structures 104 along with a plurality of horizontal mounting structures 106 .
- the tensioning section frame 102 comprises two horizontal mounting structures 106 A,B and seven vertical mounting structures 104 A-G.
- the vertical mounting structures 104 A-G are equally spaced from one another and extend vertically between the two horizontal mounting structures 106 A,B.
- a plurality of adjustable drag members 150 are mounted on the plurality of vertical mounting structures 104 A-G.
- three adjustable drag members 150 A,B,C are mounted on a first vertical mounting structure 104 A and seven adjustable drag members 150 D-J are mounted on a second vertical mounting structure 104 B.
- the remainder of the plurality of adjustable drag members 150 are similarly situation among the remaining vertical mounting structures 104 C-G.
- a total of forty one (41) adjustable drag members 150 are provided along the plurality of vertical mounting structures 104 A-G.
- the tensioning section frame 102 may be provided with more or less than forty-one adjustable drag members 150 .
- the plurality of spools 130 are removably attached to the plurality of adjustable drag members 150 .
- a first spool 130 A is attached to a first adjustable drag member 150 A and a second spool 130 B is attached to a second adjustable drag member 150 B.
- each adjustable drag member 150 is individually adjustable (i.e., manually or automatic) so as to adjust an amount of drag that each drag member 150 can provide to the susceptor coil assembly 20 during the fabrication of a ribbon 30 .
- the adjustable drag member 150 comprises a slip-clutch mechanism 160 .
- Such a slip-clutch mechanism 160 allows the length of the at least one of the plurality of susceptor coil assemblies 20 wound on the spool 130 to slip as the susceptor coil assembly 20 is pulled from the tensioning section 100 towards the impaling section 300 .
- Such a slip-clutch mechanism 160 is advantageous as it helps to prevent excessive tension (and perhaps breakage) of the susceptor coil assembly 20 during the fabrication of ribbon 30 .
- such a slip-clutch mechanism 160 is typically utilized in fishing reels.
- FIG. 7 is a diagrammatic representation of a slip clutch mechanism 160 that may be used as an adjustable drag member 150 with the tensioning section 100 illustrated in FIGS. 5 and 6 .
- the slip clutch mechanism 160 comprises a spool 162 containing susceptor coil assembly 20 that is positioned between a first side plate 164 and a second side plate 166 .
- the mechanism further comprises a handle 168 , a free spool release (i.e., an eccentric lever) 170 , and a star drag adjusting member 172 .
- the star drag adjusting member 172 comprises a mechanical device that allows the slip clutch mechanism 160 to apply variable tension to the susceptor coil assembly provided on the spool 162 in order to act as a variable friction brake. This allows a variable resistance to be applied to the susceptor coil assembly after the take up section 400 has begun to pull the plurality of susceptor coil assemblies from the tensioning section 100 and into the collimating section 200 without the susceptor coil assemblies 20 being stretched or breaking.
- a slip clutch mechanism 160 typically consist of any number of discs (e.g., drag washers) arranged in a stack on the spool shaft or in some cases, on the drive shaft. There is generally a screw or lever mechanism that presses against the washers: the higher the pressure, the greater the resistance.
- the slip clutch mechanism 160 further comprises a separate free spool release 170 that allows the slip clutch mechanism 160 to go into free spool by disengaging the spool 162 from the drive train completely. This allows the spool 162 to spin freely with little resistance.
- the free spool position may be used for setting up the apparatus 10 , allowing an operator of the apparatus to freely position the susceptor coil assemblies 20 throughout the various sections 100 , 200 , 300 , 400 , and 500 of apparatus 10 .
- each adjustable drag member 150 is provided with a separate susceptor coil assembly 20 (like the slip clutch mechanism 160 illustrated in FIG. 7 ), these plurality of drag members 150 allow the tensioning section 100 to maintain a desired tension in each of the plurality of susceptor coil assemblies 20 as the plurality of susceptor coil assemblies 20 are pulled from the tensioning section 100 , into the collimating section 200 , and then into the impaling section 300 .
- the take up section 400 may draw or pull the susceptor coil assembly ribbon 30 from the impaling section 300 .
- the take up section 400 may draw the susceptor coil assembly ribbon 30 from the slitting section 500 .
- the tensioning section frame 102 is releasably attached to the base 800 of the apparatus 10 .
- the tensioning section frame 102 is releasably attached to the base 800 of the apparatus 10 by way of a plurality of dampening tubes 110 A,B,C.
- this exemplary apparatus 10 utilizes three dampening tubes 110 A,B,C.
- dampening tubes 110 A,B,C provide a number of advantages.
- these dampening tubes 110 A,B,C help to reduce oscillations that may occur as the susceptor coil assemblies 20 are pulled from the tensioning section frame 105 during ribbon 30 fabrication.
- the apparatus 10 further includes a collimating section 200 that resides downstream of the tensioning section 100 .
- the collimating section 200 comprises a plurality of guide tubes 205 , an arch structure 210 , and a multi-grooved aligning member 215 .
- the arch structure 210 is mounted to the top surface 820 of the base 800 and is configured to retain the plurality of guide tubes 205 .
- FIG. 8 is a diagrammatic representation of a portion of the collimating section 200 illustrated in FIG. 4 .
- FIG. 8 is a diagrammatic representation of the plurality of guide tubes 205 illustrated in FIG. 4 .
- each of the plurality of guide tubes 205 are inserted into one of a plurality of recesses 212 defined by the arch structure 210 .
- a first guide tube 205 A is inserted into a first recess 212 A defined by the arch structure 210 and a second guide tube 205 B is inserted into a second recess 212 B defined by the arch structure 210 .
- the arch structure 210 comprises fifty-five (55) recesses 212 for receiving the plurality of guide tubes 205 .
- the apparatus 10 illustrated in FIGS. 4 and 8 may be utilized for guiding up to fifty-five (55) susceptor coil assemblies 20 during the fabrication of a susceptor coil assembly ribbon 30 .
- alternative ribbon arrangements having more or less than fifty-five susceptor coil assemblies 20 may also be fabricated.
- the plurality of guide tubes 205 receive a susceptor coil assembly 20 from the tensioning section 100 .
- tensioning section 100 comprises forty-one spools 130 with each spool 130 comprising a length of a susceptor coil assembly 20
- the plurality of guide tubes 205 comprise elongated cylindrical structures.
- Such elongated cylindrical structures may comprise a synthetic resin made of polymerized tetrafluoroethylene (e.g., Teflon). Polymerized tetrafluoroethylene may be beneficial in certain applications because of this synthetic resin's non-stick or low friction properties.
- the plurality of guide tubes 205 comprise 1 ⁇ 4 inch tubing. However, the size of the guide tubes 205 may vary based on the size of the susceptor coil assemblies 20 that are being guided from the tensioning section 100 and into the collimating section 200 .
- the plurality of guide tubes 205 guide or direct the plurality of susceptor coil assemblies 20 into the impaling section 300 .
- the plurality of guide tubes 205 guide the plurality of susceptor coil assemblies 20 into a multi-grooved aligning member 215 of collimating section 200 .
- FIG. 9 is a diagrammatic representation of a collimating section 200 of an apparatus for fabricating a susceptor coil assembly ribbon according to disclosed embodiments.
- a plurality of susceptor coil assemblies 20 are illustrated as entering the multi-grooved aligning member 215 of collimating section 200 .
- a first matrix material source 324 provides matrix material 320 A into the collimating section 200 of apparatus 10 .
- a second matrix material source 328 provides matrix material 320 B into the collimating section 200 of apparatus 10 .
- the multi-grooved aligning member 215 illustrated in FIG. 9 comprises a multi-grooved aligning member housing 220 that houses a rotating multi-grooved aligning member 250 .
- FIG. 10 is a diagrammatic representation of a multi-grooved aligning member housing 220 that may be used with the multi-grooved aligning member 215 illustrated in FIG. 9 .
- FIG. 11 is another diagrammatic representation of the multi-grooved aligning member housing 220 illustrated in FIG. 10 . Referring now to FIGS.
- the multi-grooved aligning member housing 220 comprises a slot member 230 , a plurality of grooves 240 , a support bar 260 , a bearing surface 280 , and an internal cavity 290 (See, FIG. 11 ).
- the internal cavity 290 is configured to receive and house the rotatable multi-grooved aligning member 250 (See, FIG. 12 ).
- the plurality of susceptor coil assemblies 20 are guided or directed by the plurality of guide tubes 205 of the tensioning section 100 into a plurality of grooves 240 defined by the multi-grooved aligning member housing 220 .
- each groove of the plurality of grooves 240 receives an individual susceptor coil assembly 20 .
- each individual groove of the plurality of grooves 240 receives an individual susceptor coil assembly 20 by way of one of the plurality of guide tubes 205 .
- the individual grooves 240 help to ensure alignment the plurality of susceptor coil assemblies 20 as the plurality of assemblies 20 channel through the plurality of grooves 240 .
- the multi-grooved aligning member housing 220 further comprises a slot member 230 .
- a matrix material 320 A from a first matrix material source 324 is provided into this slot member 230 before the matrix material 320 A is provided to the impaling section 300 (See, e.g., FIG. 9 ).
- the multi-grooved aligning member housing 220 further comprises a support bar 260 .
- the support bar 260 is positioned below the plurality of grooves 240 and is configured to support matrix material 320 B provided by the second matrix material source 328 (See, FIG. 9 ).
- the plurality of grooves 240 align the plurality of susceptor coil assemblies 20
- the slot member 230 receives matrix material 320 A from the first matrix material source 324
- the support bar 260 supports the matrix material 320 B provided by the second matrix material source 328 .
- the plurality of susceptor coil assemblies 20 are aligned by the grooves 240 of the multi-grooved aligning member housing 220 , the plurality of susceptor coil assemblies 20 are further aligned by way of the rotatable multi-grooved aligning member 250 .
- the rotatable multi-grooved aligning member 250 is positioned within the internal cavity 290 defined by the multi-grooved aligning housing 215 (See, FIG. 11 ).
- FIG. 12 is a diagrammatic illustration of the rotatable multi-grooved aligning member 250 aligning the plurality of susceptor coil assemblies 20 after the assemblies 20 have been initially aligned by the grooves 240 of the multi-grooved aligning member housing member 220 .
- the multi-grooved aligning member housing 220 is not illustrated.
- the rotatable multi-grooved aligning member 250 comprises a rotatable cylindrical structure 255 .
- the cylindrical structure 255 of the rotatable multi-grooved aligning member 250 further comprises an outer surface 252 that defines a plurality of grooves 254 .
- the rotatable multi-groove aligning member 250 comprises thirty-six (36) grooves for receiving and aligning the plurality of susceptor coil assemblies 20 .
- the impaling section 300 also receives at least one layer of a matrix material 320 .
- two sources of matrix material 320 are provided: a first matrix material source 324 providing a first matrix material 320 A and a second matrix material source 328 providing a second matrix material 320 B.
- the first matrix material 320 A may be the same as the second matrix material 320 B. In an alternative arrangement, the first matrix material 320 A may be different than the second matrix material 320 B.
- the first matrix material source 324 comprises a plurality of layers of matrix material provided on a roll 325 . As this layer of matrix material 320 A is removed from the roll 325 , the matrix material 320 A transitions over a guide roll 330 A. After the material 320 A transitions over the guide roll 330 A, the matrix material 320 A is then received by the slot member 230 of the multi-grooved aligning member housing 220 .
- the second matrix material source 328 comprises a plurality of layers of matrix material 320 B provided on a roll 329 . As these layers of matrix material 320 B are removed from the roll 329 , the matrix material 320 B transitions over a guide roll 330 B. After the matrix material 320 B transitions over the guide roll 330 B, the matrix material 320 B is received by the support bar 260 of the multi-grooved aligning member housing 220 .
- FIG. 13 is a diagrammatic representation of an impaling section 300 of an apparatus for fabricating a susceptor coil assembly ribbon 30 according to disclosed embodiments.
- FIG. 14A is a diagrammatic representation of the plurality of pinch rollers 340 illustrated FIG. 13 receiving the plurality of susceptor coil assemblies 20 , the matrix material 320 A from a first matrix material source 324 , and matrix material 320 B from a second matrix material source 328 .
- a first stationary face plate 380 A and a first movable face plate 390 A of the impaling section 300 has been removed.
- FIG. 14B is another diagrammatic representation of an impaling section 300 of an apparatus for fabricating a susceptor coil assembly ribbon 30 according to disclosed embodiments.
- the coil assemblies 20 are provided to the plurality of pinch rollers 340 .
- the plurality of pinch rollers 340 are configured to simultaneously receive the matrix material 320 A, the matrix material 320 B, and the plurality of susceptor coil assemblies 20 .
- the plurality of pinch rollers 340 comprise three pinch rollers: a first pinch roller 350 , a second pinch roller 360 , and a third pinch roller 370 .
- the first pinch roller 350 is operably coupled to the multi-grooved aligning member 215 .
- the first pinch roller 350 initially receives the matrix material 320 B that passes over the support bar 260 of the guide member housing 220 (See, e.g., FIG. 13 ).
- the first pinch roller 350 also receives the plurality of susceptor coil assemblies 20 that are aligned by the plurality of grooves 254 defined along the outer surface 252 of the rotatable multi-grooved aligning member 250 .
- the outer surface 252 of the rotatable multi-grooved aligning member 250 acts together with an outer surface 352 of the first pinch roller 350 so as to initially compress press or pinch the susceptor coil assemblies 20 and the matrix material 320 B together (See, e.g., FIG. 14B ).
- the matrix material 320 A passes into the slot member 230 of the aligning member housing 220 (See, e.g., FIG. 13 ), the matrix material 320 A passes along an outer surface 362 of the second pinch roller 360 (See, e.g., FIGS. 14A and 14B ).
- the outer surface 362 of the second pinch roller 360 and the outer surface 352 of the first pinch roller 350 act together to initially compress or pinch the plurality of susceptor assemblies 20 between matrix material 320 A and matrix material 320 B.
- this susceptor coil assembly ribbon depth 35 is a function of a pinch roller distance or gap 342 that is adjustable between the outer surface 362 of the second pinch roller 360 and the outer surface 372 of the third pinch roller 370 .
- the apparatus 10 comprises an adjusting mechanism 378 that allows for the pinch roller gap 342 between outer surface 362 of the second pinch roller 360 and the outer surface 372 of the third pinch roller 370 to be adjusted.
- the impaling section 300 comprises a first stationary plate 380 A and a second stationary plate 382 B. (only the first stationary face plate 380 A is fully illustrated in FIG. 13 ).
- the first pinch roller 350 and third pinch roller 370 are positioned between a first stationary face plate 380 A and a second stationary face plate 380 B.
- the first and second stationary face plates 380 A,B are configured to contain a rotating shaft 355 of the first pinch roller 350 and a rotating shaft 375 of the third pinch roller 370 .
- the stationary face plates 380 A,B further comprise horizontal mounting plates 382 A,B, respectively that allows the plurality of pinch rollers 340 to be mounted to the top face 820 of the apparatus base. (See, FIG. 4 )
- the first and second stationary face plates 380 A,B prevent certain undesired movement of the first pinch roller 350 with respect to the third pinch roller 370 .
- the impaling section 300 further comprises a first movable face plate 390 A and a second movable face plate 390 B.
- FIG. 13 illustrates only the first moveable face plate 390 A.
- the first movable face plate 390 A is configured to contain a rotating shaft 365 of the second pinch roller 360 and the rotating shaft 375 of the third pinch roller 370 .
- the rotating shaft 375 of the third pinch roller 370 acts as a pivot point 376 for the first movable face plate 390 A by way of a spring force 396 acting on an arm portion 392 of the first movable face plate 390 A.
- a predetermine amount of compression can be exerted between the outer surface 352 of the first pinch roller 350 and the outer surface 362 of the second pinch roller 360 (See, FIGS. 14A and B).
- the second movable face plate 390 B acts in a similar fashion as the first movable face plate 390 A herein described.
- first adjusting plate 490 A Mounted along an external surface 398 A of the first movable face plate 390 A is a first adjusting plate 490 A.
- a similar adjusting plate 490 B is mounted on an external surface 398 B of the second movable face plate 390 B.
- Both the first and the second adjusting plates 490 A,B can be adjusted so as to move the first and second adjusting plates 490 A,B (and therefor the rotating shaft 365 of the second pinch roller 360 ) along the A-B direction as illustrated in FIG. 14A .
- movement of the first and second adjusting plates 490 A,B allows the pinch roller distance 342 between the outer surface 362 of the second pinch roller 360 and the outer surface 372 of the third pinch roller 370 to be adjusted to a desired distance.
- this distance 342 between these outer surfaces 362 , 372 may be varied by way of a first adjusting screw 386 A for the first adjusting plate 490 A and a second similar adjusting screw 386 B for the second adjusting plate 490 B.
- FIG. 15 illustrates a diagrammatic representation of the first adjusting plate 490 A illustrated in FIG. 13 .
- the first adjusting plate 490 A resides along the external surface 398 A of the first movable face plate 390 A.
- FIG. 16 is diagrammatic representation of the first adjusting plate 490 A illustrated in FIG. 15 .
- the first adjusting plate 490 A is generally rectangular in shape and defines a circular recess 492 A for receiving the rotating shaft 365 of the second pinch roller 360 .
- the adjusting plate 490 A further comprises a first slot or groove 494 A and a second slot or groove 496 A. These slots or grooves 494 A,B are defined along first and second outer edges of the adjusting plate 490 A.
- the first and second slots 494 A, 496 A are configured to engage a first tongue 394 A and second tongue 395 A of the first moveable face plate 390 A, respectively.
- FIG. 17 illustrates the first and second tongues 394 A, 395 A of the first movable face plate 390 A.
- the second adjusting plate 490 B can be moved in a similar manner.
- the distance 342 between the outer surface 362 of the second pinch roller 360 and the outer surface 372 of the third pinch roller 370 may be adjusted.
- Such an adjustment mechanism 378 allows for a resulting ribbon 30 to comprise a predetermined ribbon depth 35 based on this adjustable distance 342 .
- FIG. 18 a diagrammatic representation of a take up section 400 of the apparatus 10 illustrated herein.
- FIG. 19 a diagrammatic representation of a take up spool 450 of the take up section 400 illustrated in FIG. 18 .
- the take up section 400 is positioned downstream of the impaling section 300 and receives the susceptor coil assembly ribbon 30 from the impaling section 300 .
- the take up section 400 comprises a take up spool 450 , a computing device 725 , and a programmable drive system 460 .
- the programmable drive system 460 comprises a programmable drive 430 and a take up motor 470 .
- An encoder is provided on an output shaft of the take up motor 470 .
- a programmable drive system 460 is mounted to the take up spool 450 .
- the programmable drive system 460 is programmable to operate a programmable drive 430 and a take up motor 470 to achieve a desired feed rate of the plurality of susceptor coil assemblies 20 from the tensioning section 100 to the impaling section 300 .
- the take up motor 470 comprises a smart motor such as an induction motor comprising an integral encoder that provides position shaft position feedback to the system software 700 .
- the programmable drive system 460 may be operated and controlled by way of a computing device 725 running the system software 700 .
- the method further includes the step 1040 of collimating the plurality of susceptor coil assemblies 20 as the plurality of susceptor coil assemblies 20 are pulled from the tensioning section 100 towards a collimating section 200 .
- the step of collimating may include the step of aligning the plurality of susceptor coil assemblies 20 .
- the method includes the step 1050 of utilizing a multi-grooved aligning member housing 220 comprising a plurality of grooves 240 to align the plurality of susceptor coil assemblies 20 as the plurality of susceptor coil assemblies 20 are pulled from the tensioning section 100 and into the impaling section 300 .
- the method further includes the step 1060 of impaling the plurality of susceptor coil assemblies 20 into a matrix material 320 so as to fabricate a susceptor coil assembly ribbon 30 .
- impaling the plurality of susceptor coil assemblies 20 into a matrix material 320 so as to fabricate a susceptor coil assembly ribbon 30 may comprise impaling the plurality of susceptor coil assemblies 20 into at least one layer of the matrix material 320 .
- the matrix material 320 may be provided by a first matrix material source 324 .
- the matrix material 320 may be provided by a first matrix material source 324 and a second matrix material source 328 .
- FIG. 21 is an illustration of a perspective view of an aircraft 1600 that may incorporate one or more composite laminate structures heated by a heating blanket incorporating one of the susceptor coil assembly ribbon embodiments of the present disclosure.
- the aircraft 1600 comprises a fuselage 1612 , a nose 1614 , a cockpit 1616 , wings 1618 operatively coupled to the fuselage 1620 , one or more propulsion units 1620 , a tail vertical stabilizer 1622 , and one or more tail horizontal stabilizers 1624 .
- the aircraft 1600 shown in FIG. 21 is generally representative of a commercial passenger aircraft, heating blankets comprising one or more susceptor coil assemblies as disclosed herein, may also be employed in other types of aircraft or air vehicles. More specifically, the teachings of the disclosed embodiments may be applied to other passenger aircraft, cargo aircraft, military aircraft, rotorcraft, and other types of aircraft or aerial vehicles, as well as aerospace vehicles, satellites, space launch vehicles, rockets, and other aerospace vehicles.
- embodiments of structures and methods in accordance with the disclosure may be utilized in other transport vehicles, such as boats and other watercraft, trains, automobiles, trucks, buses, or other suitable transport vehicles heated by susceptor coil assembly based heating blankets as disclosed herein.
- Embodiments of the disclosure may find use in a variety of potential applications, particularly in the transportation industry, including for example, aerospace, marine, automotive applications and other application where thermoplastic composite tubular structures may be used. Therefore, referring now to FIGS. 22 and 23 , embodiments of the disclosure may be used in the context of an aircraft manufacturing and service method 1630 as shown in FIG. 22 and an aircraft 1650 as shown in FIG. 23 .
- Aircraft applications of the disclosed embodiments may include, for example, without limitation, the design and fabrication of composite laminates fabricated by way of a releasable support as disclosed herein.
- component and subassembly manufacturing 1636 and system integration 1638 of the aircraft 1650 takes place.
- the aircraft 1650 may go through certification and delivery 1640 in order to be placed in service 1642 .
- the aircraft 1650 is scheduled for routine maintenance and service 1644 , which may also include modification, reconfiguration, refurbishment, and so on.
- a system integrator may include without limitation any number of aircraft manufacturers and major-system subcontractors; a third party may include without limitation any number of vendors, subcontractors, and suppliers; and an operator may be an airline, leasing company, military entity, service organization, and so on.
- the aircraft 1650 produced by exemplary method 1630 may include an airframe 1652 with a plurality of high-level systems 1654 and an interior 1656 .
- high-level systems 1654 may include one or more of a propulsion system 1658 , an electrical system 1660 , a hydraulic system 1662 , and an environmental system 1664 . Any number of other systems may be included.
- an aerospace example is shown, the principles of the disclosure may be applied to other industries, such as the marine and automotive industries.
- Systems and methods embodied herein may be employed during any one or more of the stages of the production and service method 1630 .
- components or subassemblies corresponding to production process may be fabricated or manufactured in a manner similar to components or subassemblies produced while the aircraft 1650 is in service.
- one or more apparatus embodiments, method embodiments, or a combination thereof may be utilized during the production stages 1632 and 1634 , for example, by substantially expediting assembly of or reducing the cost of an aircraft 1650 .
- apparatus embodiments, method embodiments, or a combination thereof may be utilized while the aircraft 1650 is in service, for example and without limitation, to maintenance and service 1644 .
Abstract
Description
- The present disclosure relates generally to susceptors for use with heating blankets. More particularly, the present disclosure relates to methods and apparatus for fabricating a susceptor coil assembly ribbon wherein the ribbon comprises a plurality of susceptor coil assemblies.
- A composite part may be bonded or cured in an oven or an autoclave where heat is applied to the part while supported on a cure tool that maintains the shape of the part during the curing process. Techniques have been developed for curing composite parts without the need for an oven or autoclave. However, these techniques have been limited to curing relatively small, simple parts and/or require relatively complicated and/or expensive tooling. Recently, curing of relatively small composite parts has been achieved using induction heating equipment employing ferromagnetic susceptors that produce a maximum, constant temperature when inductively heated. For example, heating blankets using inductively heated susceptors have been used to cure relatively small areas of a composite rework patch applied to a structure such as an aircraft skin.
- In certain known heating blankets, the blankets are constructed by threading springs of susceptor wire onto a length of a conductor wire that is designed for carrying high frequency current, commonly referred to in the art as a Litz wire. When threading the susceptor wire onto the conductor wire, it is generally desired to orient the susceptor wire as near to perpendicular as possible to the direction of current flow in the Litz wire. A near perpendicular orientation is desired so as to maximize the induced magnetic fields into the susceptor wire which creates heat by virtue of eddy currents created by the wire. By using springs (i.e., pre-formed or wrapped onto the Litz wire), the susceptor can be oriented along the Litz wire in order to capitalize on a high density of susceptor per unit length of the Litz wire and keep the susceptor wire in the region of highest magnetic field strength (i.e., as close to orthogonal to the direction of current flow within the Litz wire).
- This threaded spring configuration has been shown to produce suitable results for certain heating blanket applications, but also has demonstrated certain limitations. For example, in such spring configurations, a large amount of Litz wire is typically required to carry the appropriate amount of current for large heating blankets. In addition, a large amount of Litz wire is typically also required to maintain an applied voltage within certain safety levels, and also to produce the required amount of heat. Therefore, the spring threaded configurations do not lend themselves to providing a practical heating blanket for large heating or curing applications. Moreover, is has been proven difficult to keep the susceptor springs from tangling with one another within the heating blanket. In addition, susceptor springs were not cost effective for large sized heating blankets.
- Accordingly, there is a need for cost effective methods and devices that can be utilized to fabricate susceptor based heating blankets while customizing such blankets so as to achieve desired heating profiles, especially for heating large composite structures.
- According to an exemplary embodiment, an
apparatus 10 for fabricating a susceptorcoil assembly ribbon 30 is disclosed. Theapparatus 10 comprising atensioning section 100 that provides a predetermined amount of tension to a plurality ofsusceptor coil assemblies 20, acollimating section 200 that receives the plurality ofsusceptor coil assemblies 20 from thetensioning section 100 and aligns the plurality ofsusceptor coil assemblies 20 and animpaling section 300 that receives the plurality ofsusceptor coil assemblies 20 aligned by thecollimating section 200 and impales the plurality of susceptor coil assemblies 20 into amatrix material 320 so as to fabricate a susceptorcoil assembly ribbon 30. - In an exemplary arrangement, the
apparatus 10 further comprises a take upsection 400 for receiving the susceptorcoil assembly ribbon 30 from theimpaling section 300, the take upsection 400 winding the susceptorcoil assembly ribbon 30 onto a take upspool 450. - In an exemplary arrangement, the take up
section 400 comprises aprogrammable drive system 460 that is programmable to operate a take upmotor 470, preferably a smart motor 475. The take upmotor 470 is operable to pull the plurality of susceptor coil assemblies 20 from thetensioning section 100 through theimpaling section 300. - In an exemplary arrangement, the
tensioning section 100 comprises a plurality ofspools 130 wherein each of the plurality ofspools 130 is wound with a length of one of the plurality ofsusceptor coil assemblies 20. In an exemplary arrangement, at least one of the plurality ofspools 130 is mounted to anadjustable drag member 150. In an exemplary arrangement, theadjustable drag member 150 comprises a slip-clutch mechanism 160. The slip-clutch mechanism 160 allows the length of the at least one of the plurality of susceptor coil assemblies wound on the spool to slip as the plurality ofsusceptor coil assemblies 30 are pulled from thetensioning section 100 towards theimpaling section 300. - In an exemplary arrangement, the
collimating section 200 comprises a multi-grooved aligningmember 215. The aligningmember 215 comprising a plurality ofgrooves 240 that are configured to align the plurality ofsusceptor coil assemblies 120 as the plurality ofsusceptor coil assemblies 120 are pulled from thetensioning section 100 and into theimpaling section 300. - In an exemplary arrangement, the
impaling section 300 comprises a plurality ofpinch rollers 340 that receive the plurality ofsusceptor coil assemblies 20 aligned by thecollimating section 200 and that impales the plurality of susceptor coil assemblies 20 into thematrix material 320 so as to fabricate the susceptorcoil assembly ribbon 30. - In an exemplary arrangement, the plurality of
pinch rollers 340 impales the plurality of susceptor coil assemblies 20 into thematrix material 320 so as to fabricate the susceptorcoil assembly ribbon 30. Preferably, the susceptorcoil assembly ribbon 30 comprises apre-determined depth 35. - In an exemplary arrangement, the
apparatus 10 further comprises at least a firstmatrix material source 324. In another exemplary arrangement, theapparatus 10 further comprises at least a firstmatrix material source 324 and a secondmatrix material source 328. - In an exemplary arrangement, the
impaling section 300 that receives the plurality ofsusceptor coil assemblies 20 aligned by thecollimating section 200, impales the plurality of susceptor coil assemblies 20 into at least one layer of thematrix material 320 so as to fabricate a susceptorcoil assembly ribbon 30. - In an exemplary arrangement, the apparatus comprises a
slitting section 500 that receives the susceptorcoil assembly ribbon 30 from theimpaling section 300 and slits the susceptorcoil assembly ribbon 30 to a desired susceptor coil assembly width 40. - In an exemplary arrangement, a method for fabricating a susceptor
coil assembly ribbon 30 is disclosed. The method comprising the steps of pulling a plurality of susceptor coil assemblies 20 from atensioning section 100 towards acollimating section 300. The method includes the steps of collimating the plurality ofsusceptor coil assemblies 20 as the plurality ofsusceptor coil assemblies 20 are pulled from thetensioning section 100 towards acollimating section 200 so as to align the plurality ofsusceptor coil assemblies 20 and impaling the plurality of susceptor coil assemblies 20 into amatrix material 320 so as to fabricate a susceptorcoil assembly ribbon 30. - In an exemplary arrangement, the method further comprises the step of receiving the susceptor
coil assembly ribbon 30 from theimpaling section 300 by a take upsection 400, the take upsection 400 comprising a take upspool 450 and winding the susceptorcoil assembly ribbon 30 onto the take upspool 450. - In an exemplary arrangement, the method further comprises the step of utilizing a
programmable drive system 460 to pull the plurality ofsusceptor coil assemblies 20 from thetensioning section 100 through theimpaling section 300, theprogrammable drive system 460 is programmable to operate a take upmotor 470. - In an exemplary arrangement, the method further comprises the step of utilizing a multi-grooved aligning
member 215 comprising a plurality ofgrooves 240 to align the plurality ofsusceptor coil assemblies 20 as the plurality ofsusceptor coil assemblies 20 are pulled from thetensioning section 100 and into theimpaling section 300. - In an exemplary arrangement, the method further comprises the step of maintaining a desired tension in the plurality of
susceptor coil assemblies 20 as the plurality ofsusceptor coil assemblies 20 are pulled from thetensioning section 100 towards thecollimating section 200. - In an exemplary arrangement, the step of impaling the plurality of susceptor coil assemblies 20 into a
matrix material 320 so as to fabricate a susceptorcoil assembly ribbon 30 comprises the step of impaling the plurality of susceptor coil assemblies 20 into at least one layer of thematrix material 320 so as to fabricate a susceptorcoil assembly ribbon 30. - In an exemplary arrangement, the method further comprises the step of winding the susceptor coil assembly ribbon 30 onto a take up
spool 450. - In an exemplary arrangement, the method further comprises the step of slitting the susceptor
coil assembly ribbon 30 to a desired susceptor coil assembly ribbon width 40. - These as well as other advantages of various aspects of the present patent application will become apparent to those of ordinary skill in the art by reading the following detailed description, with appropriate reference to the accompanying drawings.
- The novel features believed characteristic of the illustrative embodiments are set forth in the appended claims. The illustrative embodiments, however, as well as a preferred mode of use, further structures and descriptions thereof, will best be understood by reference to the following detailed description of an illustrative embodiment of the present disclosure when read in conjunction with the accompanying drawings, wherein:
-
FIG. 1 is a diagrammatic representation of a functional block diagram of a apparatus for fabricating a susceptor coil assembly ribbon according to disclosed embodiments; -
FIG. 2 is a diagrammatic representation of a susceptor coil assembly that may be utilized by an apparatus to fabricate a susceptor coil assembly ribbon, such as the apparatus represented by the functional block diagram ofFIG. 1 ; -
FIG. 3 is a diagrammatic representation of an example computing device, according to one embodiment; -
FIG. 4 is a diagrammatic representation of an apparatus for fabricating a susceptor coil assembly ribbon according to disclosed embodiments; -
FIG. 5 a diagrammatic representation of a tensioning section of the apparatus ofFIG. 4 ; -
FIG. 6 is another diagrammatic representation of a tensioning section of the apparatus ofFIG. 4 ; -
FIG. 7 is a diagrammatic representation of a slip clutch mechanism that may be used with the tensioning section illustrated inFIGS. 5 and 6 [TW1] [k2]; -
FIG. 8 is a diagrammatic representation of a portion of the collimating section of an apparatus for fabricating a susceptor coil assembly ribbon according to disclosed embodiments; -
FIG. 9 is a diagrammatic representation of a collimating section of an apparatus for fabricating a susceptor coil assembly ribbon according to disclosed embodiments; -
FIG. 10 is a diagrammatic representation of a multi-grooved aligning member of the collimating section illustrated inFIG. 9 ; -
FIG. 11 is a diagrammatic representation of the multi-grooved aligning member housing illustrated inFIG. 10 ; -
FIG. 12 is a diagrammatic representation of rotating multi-grooved aligning member that is configured to operate with the multi-grooved aligning member illustrated inFIG. 10 ; -
FIG. 13 is a diagrammatic representation of an impaling section of an apparatus for fabricating a susceptor coil assembly ribbon according to disclosed embodiments; -
FIG. 14A is another diagrammatic representation of an impaling section of an apparatus for fabricating a susceptor coil assembly ribbon according to disclosed embodiments; -
FIG. 14B is another diagrammatic representation of an impaling section of an apparatus for fabricating a susceptor coil assembly ribbon according to disclosed embodiments; -
FIG. 15 is a diagrammatic representation of an adjusting plate used to adjust the positions of the pinch rollers illustrated inFIG. 14 ; -
FIG. 16 is another diagrammatic representation of an adjusting plate for use with a plurality of pinch rollers as disclosed herein; -
FIG. 17 is another diagrammatic representation of an impaling section as disclosed herein; -
FIG. 18 a diagrammatic representation of a take up section illustrated inFIG. 4 ; -
FIG. 19 a diagrammatic representation of a take up spool of the take up section illustrated inFIG. 18 ; -
FIG. 20 illustrates steps of a method of fabricating a susceptor coil assembly ribbon, such as the susceptor coil assembly ribbon disclosed herein; -
FIG. 21 is a diagrammatic representation of a perspective view of an aircraft that may incorporate one or more composite laminate structures manufactured in accordance with one or more embodiments disclosed herein; -
FIG. 22 is a diagrammatic representation of a flow diagram of aircraft production and service methodology; and -
FIG. 23 is a diagrammatic representation of a block diagram of an aircraft. -
FIG. 1 is a diagrammatic representation of a functional block diagram of anapparatus 10 for fabricating a susceptorcoil assembly ribbon 30 according to disclosed embodiments. As will be described in greater detail herein, the susceptorcoil assembly ribbon 30 comprises a plurality of susceptor coil assemblies 20 (i.e., a smart susceptor that is wound or coiled generally perpendicularly along an outer surface of a conductor wire where the wound coils reside perpendicular to a longitudinal axis of the conductor wire e.g., a Litz wire). For example, corresponding patent disclosure entitled “Method and Apparatus For Fabricating Susceptor Coil Assemblies,” filed simultaneously along with the present disclosure, generally describes methods and apparatus for fabricating such susceptor coil assemblies. This corresponding patent disclosure is herein entirely incorporated by reference and to which the reader is directed for further information. The disclosedapparatus 10 impales (i.e., imbeds) the plurality ofsusceptor coil assemblies 20 within a matrix material 320 (e.g., a B-stage silicon rubber) to thereby fabricate the susceptorcoil assembly ribbon 30. - For example, an exemplary
susceptor coil assembly 20 is illustrated inFIG. 2 . A plurality of suchsusceptor coil assemblies 20 may be embedded within one or more layers of amatrix material 320 so as to form a susceptorcoil assembly ribbon 30. Theribbon 30 may then be slit to a desired ribbon width 40 and then theribbon 30 may be wound by a take upsection 400. Optionally, theribbon 30 and itsmatrix material 320 may then be heated and cured. The curedribbon 30 may then be used in for a range of heating applications, such as a heating blanket for heating composite structures. - In this illustrated
susceptor coil assembly 20 ofFIG. 2 , theassembly 20 comprises a spring or coil shapedsusceptor 22 that is wound around anouter surface 26 of aconductor wire 24 as described in Applicants' related application entitled “Method and Apparatus For Fabricating Susceptor Coil Assemblies,” previously herein entirely incorporated by reference. In one preferred arrangement, theconductor wire 24 comprises a Litz wire. As will be described in greater detail herein, theapparatus 10 illustrated inFIG. 1 can be used to fabricate a susceptorcoil assembly ribbon 30 wherein the number and/or the type ofsusceptor coil assemblies 20 can be varied so as to fabricate a diverse variety of susceptorcoil assembly ribbon 30 arrangements. As just one example, thesusceptor coil assembly 20 illustrated inFIG. 2 comprises a total number of 12 turns of the susceptor wire 21 that are provided along alength L 28 of theconductor wire 24. One advantage of the presently disclosed apparatus and/or methods is that the apparatus can be utilized to fabricate a susceptorcoil assembly ribbon 30 comprising from about 10 to about 100susceptor coil assemblies 20 impaled within at least onematrix material 320. - Returning to
FIG. 1 , as illustrated, theapparatus 10 for fabricating a susceptorcoil assembly ribbon 30 comprises three processing sections: atensioning section 100, acollimating section 200, and animpaling section 300. Optionally, theapparatus 10 may include aslitting section 500. Theslitting section 500 can be operated to slit the fabricatedribbon 30 to a desired ribbon width 40. In addition, take upsection 400 may be used to wind theribbon 30 that it receives from either theslitting section 500 or from theimpaling section 300. In one arrangement, the take upsection 400 winds theribbon 30 onto a take upspool 450. - One or more of the
apparatus sections computing device 725. - The
tensioning section 100 comprises a susceptorcoil assembly supply 120. Such asupply 120 may comprise a plurality ofsusceptor coil assemblies 20. In one arrangement, thesusceptor coil assemblies 20 of the susceptorcoil assembly supply 120 are provided by way of a plurality ofspools 130. In such an arrangement, each of the plurality ofspools 130 is provided with a length of asusceptor coil assembly 20. As just one example, thetensioning section 100 may comprise up to 50 ormore spools 130, with eachspool 130 wound with a length ofsusceptor coil assembly 20. - Preferably, the
tensioning section 100 maintains a desired tension in each of the plurality ofsusceptor coil assemblies 20 as the plurality ofsusceptor coil assemblies 20 are pulled from thetensioning section 100, through thecollimating section 200, and into theimpaling section 300. The take upsection 400 may draw or pull the susceptorcoil assembly ribbon 30 from theimpaling section 300. Alternatively, where aslitting section 500 is utilized, the take upsection 400 may draw the susceptorcoil assembly ribbon 30 from theslitting section 500. - The
tensioning section 100 further comprises a plurality ofadjustable drag members 150. Preferably, eachadjustable drag member 150 comprises aspool 130 ofsusceptor coil assembly 20. In an exemplary arrangement, at least one of the plurality ofspools 130 is mounted to anadjustable drag member 150. In an exemplary arrangement, theadjustable drag member 150 comprises a variable slip or frictionclutch mechanism 160. This type of slipclutch mechanism 160 allows the length of the at least one of the plurality ofsusceptor coil assemblies 20 wound on thespool 130 to slip as the plurality ofsusceptor coil assemblies 20 are pulled from thetensioning section 100 towards the impalingsection 500. As such, the amount of tension in eachsusceptor coil assembly 20 can be independently set by way of theadjustable drag member 150. - A
programmable drive system 460 is programmable to operate aprogrammable drive 430 and a take upmotor 470 to achieve a desired feed rate of the plurality ofsusceptor coil assemblies 20 from thetensioning section 100 to theimpaling section 300. Preferably, the take upmotor 470 comprises a smart motor 475 such as an induction motor comprising an integral encoder that provides position shaft position feedback to thesystem software 700. In one preferred arrangement, theprogrammable drive system 460 may be operated and controlled by way of acomputing device 725 running thesystem software 700. - The
tensioning section 100, thecollimating section 200, theimpaling section 300, and the take upsection 400 may all be operated by way of thecomputing device 725 wherein thesystem software 700 may be accessible by way of a graphical user interface 750 (i.e., GUI). As just one example, thesystem software 700 may comprise a G-code logic system software provided by Moog Animatics. As will be explained in greater detail herein, theapparatus 10 comprises aprogrammable drive system 460 that may be operated so as to fabricate a susceptorcoil assembly ribbon 30 comprising a plurality of susceptor coil assemblies 20 (such as thesusceptor coil assembly 20 illustrated inFIG. 2 ) that are impaled into a matrix material 320 (e.g., one or more layers of matrix material). - In one preferred arrangement, the
various sections apparatus 10 are supported along a portion of atop surface 820 of abase 800 for support of the various components. In one preferred arrangement, thebase 800 of theapparatus 10 is further supported by anapparatus frame 900. - In this illustrated embodiment of
apparatus 10, thetensioning section 100 comprises a susceptorcoil assembly supply 120 for supplying a plurality ofsusceptor coil assemblies 20 to thecollimating section 200. Preferably, thetensioning section 100 simultaneously provides the plurality ofsusceptor coil assemblies 20 into thecollimating section 200 at a predetermined rate or feed rate. As will be described in greater detail herein, the take upsection 400 utilizes theprogrammable drive system 460 to control a take upmotor 470 that turns the take upspool 450 in a controlled manner. As the take upspool 450 is turned in a controlled manner, the ribbon 30 (and therefore the plurality ofsusceptor coil assemblies 20 making up the ribbon 30) are pulled from thetensioning section 100, into thecollimating section 200, and then through theimpaling section 300. Preferably, theprogrammable drive system 460 is operated and controlled by thesystem software 700 and whose operating settings may be accessible by way of thegraphical user interface 750. - The
apparatus 10 further includes thecollimating section 200 which resides downstream of thetensioning section 100. Thecollimating section 200 comprises amulti-grooved aligning member 215 that receives the plurality ofsusceptor coil assemblies 20 from thetensioning section 100. Themulti-grooved aligning member 215 aligns the plurality ofsusceptor coil assemblies 20 as the plurality ofassemblies 20 are channeled through a plurality ofgrooves 240 defined by themulti-grooved aligning member 215. After the plurality ofsusceptor coil assemblies 20 are aligned, theassemblies 20 enter theimpaling section 300. Aside from receiving the now aligned plurality ofsusceptor coil assemblies 20, theimpaling section 300 also receives amatrix material 320. In one preferred arrangement, theimpaling section 300 receivesmatrix material 320 from a firstmatrix material source 324 and a secondmatrix material source 328. In an alternative arrangement, theimpaling section 300 receivesmatrix material 320 from only a firstmatrix material source 324. Alternative matrix source arrangements may also be used. - The plurality of
pinch rollers 340 are configured to receive thematrix material 320 and the plurality ofsusceptor coil assemblies 20. As thematrix material 320 and the plurality ofsusceptor coil assemblies 20 are pulled through thepinch rollers 340 by operation of the take upmotor 470, the plurality ofsusceptor coil assemblies 20 are impaled or embedded into thematrix material 320 as both the plurality ofsusceptor coil assemblies 20 and thematrix material 320 are pinched between thepinch rollers 340. Consequently, a susceptorcoil assembly ribbon 30 is fabricated. Preferably, theribbon 30 is fabricated comprising a desiredribbon depth 35. In one preferred arrangement, the desiredribbon depth 35 is determined by an adjustable distance between anouter surface 362 of afirst pinch roller 360 and anouter surface 372 of asecond pinch roller 370. As such, theimpaling section 300 produces a susceptorcoil assembly ribbon 30 comprising apredetermined depth 35. - In one arrangement, a
slitting section 500 is positioned downstream of theimpaling section 300 and receives the fabricated susceptorcoil assembly ribbon 30 from theimpaling section 300. Theslitting section 500 is operated to slit theribbon 30 to a desired ribbon width 40. Theribbon 30 comprising a desired or predetermined width 40 may then be provided to the take upsection 400 where theribbon 30 is then wound up on a take upspool 450. - Alternatively, the take up
section 400 is positioned downstream of theimpaling section 300 and receives the fabricated susceptorcoil assembly ribbon 30 directly from theimpaling section 300. - The take up
section 400 comprises a take upspool 450 and aprogrammable drive system 460. Theprogrammable drive system 460 comprises aprogrammable drive 430 and a take upmotor 470. By way of aprogrammable drive system 460, thetensioning section 100 is programmed by way of agraphical user interface 750 provided by acomputing device 725 so as to maintain a desired speed of the plurality ofsusceptor coil assemblies 20 as thesecoil assemblies 20 are pulled from thetensioning section 100 through thecollimating section 200 and towards the impalingsection 300. -
FIG. 3 illustrates a schematic drawing of anexample computing device 725. Thecomputing device 725 illustrated inFIG. 3 may represent thecomputing device 725 for use with theapparatus 10 illustrated inFIG. 1 . In some examples, components illustrated inFIG. 3 may be distributed across multiple computing devices. However, for the sake of example, the components are shown and described as part of oneexample computing device 725. - The
computing device 725 may include aninterface 727, awireless communication component 729, sensor(s) 731,data storage 733, and aprocessor 735. Components illustrated inFIG. 3 may be linked together by acommunication link 737. Thecomputing device 725 may also include hardware to enable communication between thecomputing device 725 and another computing device (not shown), such as a server entity. The hardware may include transmitters, receivers, and antennas, for example. - The
interface 727 may be configured to allow thecomputing device 725 to communicate with another computing device (not shown), such as a server or land-based device. Thus, theinterface 727 may be configured to receive input data from one or more computing devices, and may also be configured to send output data to the one or more computing devices. In some examples, theinterface 727 may also maintain and manage records of data received and sent by thecomputing device 725. Theinterface 727 may also include a receiver and transmitter to receive and send data. - The
wireless communication component 729 may be a communication interface that is configured to facilitate wireless data communication for thecomputing device 725 according to one or more wireless communication standards. For example, thewireless communication component 729 may include a Wi-Fi communication component, or a cellular communication component. Other examples are also possible, such as proprietary wireless communication devices. - The sensor(s) 731 may include one or more sensors, or may represent one or more sensors included within the
computing device 725. Example sensors may include one or more encoders, one or more accelerometers, one or more magnetometers, one or more optical sensors, and/or one or more infrared sensors, or any other similar type sensors may be incorporated into thecomputing device 725. Thesensors 731 may more generally include sensors for detecting the position of the susceptor coil assemblies, the feed rates of the coil assemblies and/or the matrix material, the torque characteristics and/or shaft speed ofmotor 450, and/or the linear speed of theribbon 30 and its various components. Thesensors 731 may also be used to track and monitor howmuch ribbon 30 has been wound on the take upspool 450. - The
processor 735 may be implemented, or realized, with a general purpose processor, a content addressable memory, a digital signal processor, an application specific integrated circuit, a field programmable gate array, any suitable programmable logic device, discrete gate or transistor logic, discrete hardware components, or any combination thereof, designed to perform the functions described herein. In this manner, a processor may be realized as a microprocessor, a computing device, a micro-computing device, a state machine, or the like. A processor may also be implemented as a combination of computing devices, e.g., a combination of a digital signal processor and a microprocessor, a plurality of microprocessors, one or more microprocessors in conjunction with a digital signal processor core, or any other such configuration. - The
data storage 733 may containprogram logic 739 andreference data 741.Reference data 741 is configured to store, maintain, and provide data as needed to support the functionality of the system. For example, thereference data 741 may comprise the type of smart susceptor used to fabricate the coil assemblies, the amount of drag provided by the plurality ofadjustable drag members 150, the type of Litz wire used, the turns per unit length of Litz wire, the size of the coil assemblies, the length of thesusceptor coil assemblies 20, and/or other types of operating data.Program logic 739, in turn, may then comprise machine language instructions or the like that are executable by theprocessor 735 to carry out various functions described herein. - In practical embodiments, the
data storage 733 may comprise, for example but without limitation, a non-volatile storage device (non-volatile semiconductor memory, hard disk device, optical disk device, and the like), a random access storage device (for example, SRAM, DRAM), or any other form of storage medium known in the art. - The
data storage 733 may be coupled to theprocessor 735 and configured to store, for example but without limitation, a database, and the like. Additionally, thedata storage 733 may represent a dynamically updating database containing a table for updating the database, and the like. Thedata storage 733 may be coupled to theprocessor 735 such that theprocessor 735 can read information from and write information to thedata storage 733. For example, theprocessor 735 may access thedata storage 733 to access a predetermined tension, a linear speed, a desired motor speed, tensioning section information, impaling section information, slitting section information, take up section information, or other data. - As an example, the
processor 735 anddata storage 733 may reside in respective application specific integrated circuits (ASICs). Thedata storage 733 may also be integrated into theprocessor 735. In an embodiment, thedata storage 733 may comprise a cache memory for storing temporary variables or other intermediate information during execution of instructions to be executed by theprocessor 735. -
FIG. 4 is a diagrammatic representation of anapparatus 10 for fabricating a susceptorcoil assembly ribbon 30 according to disclosed embodiments, similar in operation to theapparatus 10 illustrated inFIG. 1 . For example, similar to theapparatus 10 illustrated inFIG. 1 , theapparatus 10 illustrated inFIG. 4 may be used for fabricating a susceptorcoil assembly ribbon 30. As illustrated, theapparatus 10 for fabricating a susceptorcoil assembly ribbon 30 comprises three processing sections: atensioning section 100, acollimating section 200, and animpaling section 300. Optionally, theapparatus 10 may include a slitting section 500 (not shown). Theslitting section 500 can be operated to slit the fabricatedribbon 30 to a desired width 40. In addition, a take upsection 400 may be used to wind the fabricatedribbon 30 that is received from either theslitting section 500 or from theimpaling section 300. In one arrangement, the take upsection 400 winds theribbon 30 onto a take upspool 450. - Each of the
apparatus sections computing device 725 as herein described. In one preferred arrangement, thevarious sections apparatus 10 are supported along atop surface 820 of a base 800 portion for support the various components. In one preferred arrangement, thebase 800 of theapparatus 10 is further supported by anapparatus frame 900. - The
tensioning section 100 comprises a susceptorcoil assembly supply 120. In this illustrated arrangement, susceptorcoil assembly supply 120 comprises a plurality ofsusceptor coil assemblies 20 wound around a plurality ofspools 130. In this arrangement, eachspool 130 is provided with a length of asusceptor coil assembly 20. In one arrangement, eachsusceptor coil assembly 20 within the susceptorcoil assembly supply 120 comprises the same type of susceptor coil assembly 20 (i.e., the same type ofsusceptor wire 22 wrapped around theouter surface 26 of theconductor wire 24 and using the same number of wraps per inch). - However, in an alternative arrangement, the susceptor
coil assembly supply 120 may comprise different types of susceptor coil assemblies 20 (i.e., different types ofsusceptor wire 22 wrapped around different types ofconductor wire 24, and perhaps using a higher and/or lower number of wraps per inch). In such an alternative arrangement, a layout of an anticipated heating blanket and the heating blanket's heat producing requirements might dictate what type ofsusceptor coil assemblies 20 are to be provided to the plurality ofspools 130 of thetensioning section 100. A layout of an anticipated heating blanket and the heating blanket's heat producing requirements might also dictate how many of the plurality ofspools 130 of thetensioning section 100 are used during susceptorcoil assembly ribbon 30 fabrication. -
FIG. 5 a diagrammatic representation of atensioning section 100 of the apparatus ofFIG. 4 .FIG. 6 is another diagrammatic representation of atensioning section 100 of theapparatus 10 ofFIG. 4 . Referring now to bothFIGS. 5 and 6 , in this illustrated arrangement, thetensioning section 100 comprises up to fifty (50) ormore spools 130 ofsusceptor coil assemblies 20 that are mounted on atensioning section frame 102. Specifically, thetensioning section frame 102 comprises a plurality of vertical mountingstructures 104 along with a plurality of horizontal mounting structures 106. In this illustrated arrangement, thetensioning section frame 102 comprises twohorizontal mounting structures 106A,B and seven vertical mountingstructures 104A-G. In this preferred arrangement, the vertical mountingstructures 104A-G are equally spaced from one another and extend vertically between the twohorizontal mounting structures 106A,B. - A plurality of
adjustable drag members 150 are mounted on the plurality of vertical mountingstructures 104A-G. As just one example, threeadjustable drag members 150 A,B,C are mounted on a firstvertical mounting structure 104A and sevenadjustable drag members 150 D-J are mounted on a second vertical mountingstructure 104B. The remainder of the plurality ofadjustable drag members 150 are similarly situation among the remaining vertical mountingstructures 104C-G. In thistensioning section 100 arrangement illustrated inFIG. 5 , a total of forty one (41)adjustable drag members 150 are provided along the plurality of vertical mountingstructures 104A-G. As those of ordinary skill will recognize, thetensioning section frame 102 may be provided with more or less than forty-oneadjustable drag members 150. - As illustrated, the plurality of
spools 130 are removably attached to the plurality ofadjustable drag members 150. As just one example, afirst spool 130A is attached to a firstadjustable drag member 150A and asecond spool 130B is attached to a secondadjustable drag member 150B. Preferably, eachadjustable drag member 150 is individually adjustable (i.e., manually or automatic) so as to adjust an amount of drag that eachdrag member 150 can provide to thesusceptor coil assembly 20 during the fabrication of aribbon 30. In one exemplary arrangement, theadjustable drag member 150 comprises a slip-clutch mechanism 160. Such a slip-clutch mechanism 160 allows the length of the at least one of the plurality ofsusceptor coil assemblies 20 wound on thespool 130 to slip as thesusceptor coil assembly 20 is pulled from thetensioning section 100 towards the impalingsection 300. Such a slip-clutch mechanism 160 is advantageous as it helps to prevent excessive tension (and perhaps breakage) of thesusceptor coil assembly 20 during the fabrication ofribbon 30. As those of ordinary skill in the art recognize, such a slip-clutch mechanism 160 is typically utilized in fishing reels. - For example,
FIG. 7 is a diagrammatic representation of a slipclutch mechanism 160 that may be used as anadjustable drag member 150 with thetensioning section 100 illustrated inFIGS. 5 and 6 . As illustrated, the slipclutch mechanism 160 comprises aspool 162 containingsusceptor coil assembly 20 that is positioned between afirst side plate 164 and asecond side plate 166. The mechanism further comprises ahandle 168, a free spool release (i.e., an eccentric lever) 170, and a stardrag adjusting member 172. The stardrag adjusting member 172 comprises a mechanical device that allows the slipclutch mechanism 160 to apply variable tension to the susceptor coil assembly provided on thespool 162 in order to act as a variable friction brake. This allows a variable resistance to be applied to the susceptor coil assembly after the take upsection 400 has begun to pull the plurality of susceptor coil assemblies from thetensioning section 100 and into thecollimating section 200 without thesusceptor coil assemblies 20 being stretched or breaking. - As those of ordinary skill in the art will recognize, the mechanics of a slip
clutch mechanism 160 typically consist of any number of discs (e.g., drag washers) arranged in a stack on the spool shaft or in some cases, on the drive shaft. There is generally a screw or lever mechanism that presses against the washers: the higher the pressure, the greater the resistance. The slipclutch mechanism 160 further comprises a separatefree spool release 170 that allows the slipclutch mechanism 160 to go into free spool by disengaging thespool 162 from the drive train completely. This allows thespool 162 to spin freely with little resistance. The free spool position may be used for setting up theapparatus 10, allowing an operator of the apparatus to freely position thesusceptor coil assemblies 20 throughout thevarious sections apparatus 10. - Because each
adjustable drag member 150 is provided with a separate susceptor coil assembly 20 (like the slipclutch mechanism 160 illustrated inFIG. 7 ), these plurality ofdrag members 150 allow thetensioning section 100 to maintain a desired tension in each of the plurality ofsusceptor coil assemblies 20 as the plurality ofsusceptor coil assemblies 20 are pulled from thetensioning section 100, into thecollimating section 200, and then into theimpaling section 300. The take upsection 400 may draw or pull the susceptorcoil assembly ribbon 30 from theimpaling section 300. Alternatively, where aslitting section 500 is utilized in theapparatus 10 illustrated inFIG. 4 , the take upsection 400 may draw the susceptorcoil assembly ribbon 30 from theslitting section 500. - Returning to
FIGS. 4-6 , thetensioning section frame 102 is releasably attached to thebase 800 of theapparatus 10. In this preferred arrangement, thetensioning section frame 102 is releasably attached to thebase 800 of theapparatus 10 by way of a plurality of dampeningtubes 110 A,B,C. For example, thisexemplary apparatus 10 utilizes three dampeningtubes 110 A,B,C. These dampeningtubes 110 A,B,C provide a number of advantages. For example, these dampeningtubes 110 A,B,C help to reduce oscillations that may occur as thesusceptor coil assemblies 20 are pulled from the tensioning section frame 105 duringribbon 30 fabrication. - Returning to
FIG. 4 , theapparatus 10 further includes acollimating section 200 that resides downstream of thetensioning section 100. In this preferred arrangement, thecollimating section 200 comprises a plurality ofguide tubes 205, anarch structure 210, and amulti-grooved aligning member 215. As illustrated, thearch structure 210 is mounted to thetop surface 820 of thebase 800 and is configured to retain the plurality ofguide tubes 205. - For example,
FIG. 8 is a diagrammatic representation of a portion of thecollimating section 200 illustrated inFIG. 4 . Specifically,FIG. 8 is a diagrammatic representation of the plurality ofguide tubes 205 illustrated inFIG. 4 . As shown inFIG. 8 , each of the plurality ofguide tubes 205 are inserted into one of a plurality of recesses 212 defined by thearch structure 210. For example, a first guide tube 205A is inserted into a first recess 212A defined by thearch structure 210 and a second guide tube 205B is inserted into a second recess 212B defined by thearch structure 210. In this illustrated arrangement, thearch structure 210 comprises fifty-five (55) recesses 212 for receiving the plurality ofguide tubes 205. As such, theapparatus 10 illustrated inFIGS. 4 and 8 may be utilized for guiding up to fifty-five (55)susceptor coil assemblies 20 during the fabrication of a susceptorcoil assembly ribbon 30. However, as those of ordinary skill will recognize, alternative ribbon arrangements having more or less than fifty-fivesusceptor coil assemblies 20 may also be fabricated. - As noted in
FIG. 8 , the plurality ofguide tubes 205 receive asusceptor coil assembly 20 from thetensioning section 100. With this illustrated arrangement, as tensioningsection 100 comprises forty-onespools 130 with eachspool 130 comprising a length of asusceptor coil assembly 20, there are preferably forty-one guiding tubes 105 utilized by thecollimating section 200, oneguide tube 205 for eachsusceptor coil assembly 20 contained within thetensioning section 100. - As illustrated, each of the plurality of
guide tubes 205 is fixedly attached to thearch structure 210. Preferably, each of the plurality ofguide tubes 205 receives one of thesusceptor coil assemblies 20 from thetensioning section 100. Theguide tubes 205 help to individually isolate and guide the plurality ofsusceptor coil assemblies 20 from thetensioning section 100 into themulti-grooved aligning member 215 of thecollimating section 200. The plurality ofguide tubes 205 also help to align the plurality ofsusceptor coil assemblies 20 prior to impaling thesusceptor coil assemblies 20 into thematrix material 320. - In one arrangement, the plurality of
guide tubes 205 comprise elongated cylindrical structures. Such elongated cylindrical structures may comprise a synthetic resin made of polymerized tetrafluoroethylene (e.g., Teflon). Polymerized tetrafluoroethylene may be beneficial in certain applications because of this synthetic resin's non-stick or low friction properties. In one preferred arrangement, the plurality ofguide tubes 205 comprise ¼ inch tubing. However, the size of theguide tubes 205 may vary based on the size of thesusceptor coil assemblies 20 that are being guided from thetensioning section 100 and into thecollimating section 200. - The plurality of
guide tubes 205 guide or direct the plurality ofsusceptor coil assemblies 20 into theimpaling section 300. Preferably, the plurality ofguide tubes 205 guide the plurality ofsusceptor coil assemblies 20 into amulti-grooved aligning member 215 ofcollimating section 200. For example,FIG. 9 is a diagrammatic representation of acollimating section 200 of an apparatus for fabricating a susceptor coil assembly ribbon according to disclosed embodiments. As illustrated, a plurality ofsusceptor coil assemblies 20 are illustrated as entering themulti-grooved aligning member 215 ofcollimating section 200. Also illustrated inFIG. 9 , a firstmatrix material source 324 providesmatrix material 320A into thecollimating section 200 ofapparatus 10. Similarly, a secondmatrix material source 328 providesmatrix material 320B into thecollimating section 200 ofapparatus 10. - The
multi-grooved aligning member 215 illustrated inFIG. 9 comprises a multi-grooved aligningmember housing 220 that houses a rotatingmulti-grooved aligning member 250. For example,FIG. 10 is a diagrammatic representation of a multi-grooved aligningmember housing 220 that may be used with themulti-grooved aligning member 215 illustrated inFIG. 9 .FIG. 11 is another diagrammatic representation of the multi-grooved aligningmember housing 220 illustrated inFIG. 10 . Referring now toFIGS. 9, 10 and 11 , the multi-grooved aligningmember housing 220 comprises aslot member 230, a plurality ofgrooves 240, asupport bar 260, a bearingsurface 280, and an internal cavity 290 (See,FIG. 11 ). Theinternal cavity 290 is configured to receive and house the rotatable multi-grooved aligning member 250 (See,FIG. 12 ). - During fabrication of the susceptor
coil assembly ribbon 30, the plurality ofsusceptor coil assemblies 20 are guided or directed by the plurality ofguide tubes 205 of thetensioning section 100 into a plurality ofgrooves 240 defined by the multi-grooved aligningmember housing 220. Preferably, each groove of the plurality ofgrooves 240 receives an individualsusceptor coil assembly 20. More preferably, each individual groove of the plurality ofgrooves 240 receives an individualsusceptor coil assembly 20 by way of one of the plurality ofguide tubes 205. As such, theindividual grooves 240 help to ensure alignment the plurality ofsusceptor coil assemblies 20 as the plurality ofassemblies 20 channel through the plurality ofgrooves 240. - Aside from comprising a plurality of
grooves 240, the multi-grooved aligningmember housing 220 further comprises aslot member 230. In this illustrated arrangement, amatrix material 320A from a firstmatrix material source 324 is provided into thisslot member 230 before thematrix material 320A is provided to the impaling section 300 (See, e.g.,FIG. 9 ). - The multi-grooved aligning
member housing 220 further comprises asupport bar 260. As illustrated inFIGS. 9, 10, and 11 , thesupport bar 260 is positioned below the plurality ofgrooves 240 and is configured to supportmatrix material 320B provided by the second matrix material source 328 (See,FIG. 9 ). For example, and now referring toFIG. 13 , the plurality ofgrooves 240 align the plurality ofsusceptor coil assemblies 20, theslot member 230 receivesmatrix material 320A from the firstmatrix material source 324, while thesupport bar 260 supports thematrix material 320B provided by the secondmatrix material source 328. - Once the plurality of
susceptor coil assemblies 20 are aligned by thegrooves 240 of the multi-grooved aligningmember housing 220, the plurality ofsusceptor coil assemblies 20 are further aligned by way of the rotatablemulti-grooved aligning member 250. In one preferred arrangement, the rotatablemulti-grooved aligning member 250 is positioned within theinternal cavity 290 defined by the multi-grooved aligning housing 215 (See,FIG. 11 ). - For example,
FIG. 12 is a diagrammatic illustration of the rotatablemulti-grooved aligning member 250 aligning the plurality ofsusceptor coil assemblies 20 after theassemblies 20 have been initially aligned by thegrooves 240 of the multi-grooved aligningmember housing member 220. For ease of illustration, inFIG. 12 , the multi-grooved aligningmember housing 220 is not illustrated. As illustrated, the rotatablemulti-grooved aligning member 250 comprises a rotatablecylindrical structure 255. Thecylindrical structure 255 of the rotatablemulti-grooved aligning member 250 further comprises anouter surface 252 that defines a plurality ofgrooves 254. Specifically, in this illustrated arrangement, the rotatablemulti-groove aligning member 250 comprises thirty-six (36) grooves for receiving and aligning the plurality ofsusceptor coil assemblies 20. - Returning to
FIG. 9 and as noted herein, aside from receiving the now aligned the plurality ofassemblies 20 from thecollimating section 200, theimpaling section 300 also receives at least one layer of amatrix material 320. In theapparatus 10 illustrated inFIG. 4 and the impaling section illustrated inFIG. 9 , two sources ofmatrix material 320 are provided: a firstmatrix material source 324 providing afirst matrix material 320A and a secondmatrix material source 328 providing asecond matrix material 320B. - In one arrangement, the
first matrix material 320A may be the same as thesecond matrix material 320B. In an alternative arrangement, thefirst matrix material 320A may be different than thesecond matrix material 320B. Referring back toFIGS. 4 and 9 , the firstmatrix material source 324 comprises a plurality of layers of matrix material provided on aroll 325. As this layer ofmatrix material 320A is removed from theroll 325, thematrix material 320A transitions over aguide roll 330A. After thematerial 320A transitions over theguide roll 330A, thematrix material 320A is then received by theslot member 230 of the multi-grooved aligningmember housing 220. - Similarly, the second
matrix material source 328 comprises a plurality of layers ofmatrix material 320B provided on aroll 329. As these layers ofmatrix material 320B are removed from theroll 329, thematrix material 320B transitions over aguide roll 330B. After thematrix material 320B transitions over theguide roll 330B, thematrix material 320B is received by thesupport bar 260 of the multi-grooved aligningmember housing 220. -
FIG. 13 is a diagrammatic representation of animpaling section 300 of an apparatus for fabricating a susceptorcoil assembly ribbon 30 according to disclosed embodiments.FIG. 14A is a diagrammatic representation of the plurality ofpinch rollers 340 illustratedFIG. 13 receiving the plurality ofsusceptor coil assemblies 20, thematrix material 320A from a firstmatrix material source 324, andmatrix material 320B from a secondmatrix material source 328. For ease of illustration, a firststationary face plate 380A and a firstmovable face plate 390A of theimpaling section 300 has been removed. -
FIG. 14B is another diagrammatic representation of animpaling section 300 of an apparatus for fabricating a susceptorcoil assembly ribbon 30 according to disclosed embodiments. As illustrated inFIGS. 13, 14A and B, after the plurality ofsusceptor coil assemblies 20 enter thecollimating section 300, thecoil assemblies 20 are provided to the plurality ofpinch rollers 340. Preferably, the plurality ofpinch rollers 340 are configured to simultaneously receive thematrix material 320A, thematrix material 320B, and the plurality ofsusceptor coil assemblies 20. Specifically, in this illustrated arrangement, the plurality ofpinch rollers 340 comprise three pinch rollers: afirst pinch roller 350, asecond pinch roller 360, and athird pinch roller 370. - In this arrangement, the
first pinch roller 350 is operably coupled to themulti-grooved aligning member 215. Thefirst pinch roller 350 initially receives thematrix material 320B that passes over thesupport bar 260 of the guide member housing 220 (See, e.g.,FIG. 13 ). In addition, thefirst pinch roller 350 also receives the plurality ofsusceptor coil assemblies 20 that are aligned by the plurality ofgrooves 254 defined along theouter surface 252 of the rotatablemulti-grooved aligning member 250. Theouter surface 252 of the rotatablemulti-grooved aligning member 250 acts together with anouter surface 352 of thefirst pinch roller 350 so as to initially compress press or pinch thesusceptor coil assemblies 20 and thematrix material 320B together (See, e.g.,FIG. 14B ). - After the
matrix material 320A passes into theslot member 230 of the aligning member housing 220 (See, e.g.,FIG. 13 ), thematrix material 320A passes along anouter surface 362 of the second pinch roller 360 (See, e.g.,FIGS. 14A and 14B ). Theouter surface 362 of thesecond pinch roller 360 and theouter surface 352 of thefirst pinch roller 350 act together to initially compress or pinch the plurality ofsusceptor assemblies 20 betweenmatrix material 320A andmatrix material 320B. - After this initial compression, the
outer surface 362 of thesecond pinch roller 360 and theouter surface 372 of thethird pinch roller 370 act together to further compress or sandwich the plurality ofsusceptor assemblies 20 between thematrix material 320A and thematrix material 320B to fabricate a susceptorcoil assembly ribbon 30 comprising a desireddepth 35. Preferably, this susceptor coilassembly ribbon depth 35 is a function of a pinch roller distance orgap 342 that is adjustable between theouter surface 362 of thesecond pinch roller 360 and theouter surface 372 of thethird pinch roller 370. - In a preferred arrangement, the
apparatus 10 comprises anadjusting mechanism 378 that allows for thepinch roller gap 342 betweenouter surface 362 of thesecond pinch roller 360 and theouter surface 372 of thethird pinch roller 370 to be adjusted. For example, returning toFIG. 13 , theimpaling section 300 comprises a firststationary plate 380A and a secondstationary plate 382B. (only the firststationary face plate 380A is fully illustrated inFIG. 13 ). As further illustrated, thefirst pinch roller 350 andthird pinch roller 370 are positioned between a firststationary face plate 380A and a secondstationary face plate 380B. The first and secondstationary face plates 380A,B are configured to contain arotating shaft 355 of thefirst pinch roller 350 and arotating shaft 375 of thethird pinch roller 370. Thestationary face plates 380A,B further comprisehorizontal mounting plates 382A,B, respectively that allows the plurality ofpinch rollers 340 to be mounted to thetop face 820 of the apparatus base. (See,FIG. 4 ) In a preferred arrangement, the first and secondstationary face plates 380A,B, prevent certain undesired movement of thefirst pinch roller 350 with respect to thethird pinch roller 370. - The
impaling section 300 further comprises a firstmovable face plate 390A and a secondmovable face plate 390B. (FIG. 13 illustrates only the firstmoveable face plate 390A). As illustrated, the firstmovable face plate 390A is configured to contain arotating shaft 365 of thesecond pinch roller 360 and therotating shaft 375 of thethird pinch roller 370. Importantly, therotating shaft 375 of thethird pinch roller 370 acts as apivot point 376 for the firstmovable face plate 390A by way of aspring force 396 acting on anarm portion 392 of the firstmovable face plate 390A. As such, based on thisspring force 396 acting on thearm portion 392 of the firstmovable face plate 390A, a predetermine amount of compression can be exerted between theouter surface 352 of thefirst pinch roller 350 and theouter surface 362 of the second pinch roller 360 (See,FIGS. 14A and B). The secondmovable face plate 390B acts in a similar fashion as the firstmovable face plate 390A herein described. - Mounted along an
external surface 398A of the firstmovable face plate 390A is afirst adjusting plate 490A. Asimilar adjusting plate 490B is mounted on an external surface 398B of the secondmovable face plate 390B. Both the first and thesecond adjusting plates 490A,B can be adjusted so as to move the first andsecond adjusting plates 490A,B (and therefor therotating shaft 365 of the second pinch roller 360) along the A-B direction as illustrated inFIG. 14A . As such, movement of the first andsecond adjusting plates 490A,B allows thepinch roller distance 342 between theouter surface 362 of thesecond pinch roller 360 and theouter surface 372 of thethird pinch roller 370 to be adjusted to a desired distance. In this illustrated arrangement, thisdistance 342 between theseouter surfaces first adjusting screw 386A for thefirst adjusting plate 490A and a second similar adjusting screw 386B for thesecond adjusting plate 490B. -
FIG. 15 illustrates a diagrammatic representation of thefirst adjusting plate 490A illustrated inFIG. 13 . As illustrated, thefirst adjusting plate 490A resides along theexternal surface 398A of the firstmovable face plate 390A.FIG. 16 is diagrammatic representation of thefirst adjusting plate 490A illustrated inFIG. 15 . Referring now toFIGS. 15 and 16 , thefirst adjusting plate 490A is generally rectangular in shape and defines acircular recess 492A for receiving therotating shaft 365 of thesecond pinch roller 360. The adjustingplate 490A further comprises a first slot orgroove 494A and a second slot orgroove 496A. These slots orgrooves 494A,B are defined along first and second outer edges of the adjustingplate 490A. Specifically, the first andsecond slots first tongue 394A andsecond tongue 395A of the firstmoveable face plate 390A, respectively. For example,FIG. 17 illustrates the first andsecond tongues movable face plate 390A. As such, by turning the first adjustingscrew 386A, thefirst adjusting plate 490A will be moved along the first and second tongues 394AB of the firstmoveable face plate 390A. Thesecond adjusting plate 490B can be moved in a similar manner. As a result, thedistance 342 between theouter surface 362 of thesecond pinch roller 360 and theouter surface 372 of thethird pinch roller 370 may be adjusted. Such anadjustment mechanism 378 allows for a resultingribbon 30 to comprise apredetermined ribbon depth 35 based on thisadjustable distance 342. -
FIG. 18 a diagrammatic representation of a take upsection 400 of theapparatus 10 illustrated herein.FIG. 19 a diagrammatic representation of a take upspool 450 of the take upsection 400 illustrated inFIG. 18 . Referring now toFIGS. 18 and 19 , the take upsection 400 is positioned downstream of theimpaling section 300 and receives the susceptorcoil assembly ribbon 30 from theimpaling section 300. The take upsection 400 comprises a take upspool 450, acomputing device 725, and aprogrammable drive system 460. Theprogrammable drive system 460 comprises aprogrammable drive 430 and a take upmotor 470. An encoder is provided on an output shaft of the take upmotor 470. By way of aprogrammable drive system 460, the speed of the take upmotor 470 is programmed by way of thegraphical user interface 750 provided by thecomputing device 725 to maintain a desired amount of tension in the plurality ofsusceptor coil assemblies 20 as these assemblies are pulled from thetensioning section 100 towards the impalingsection 300. - As illustrated in
FIG. 19 , aprogrammable drive system 460 is mounted to the take upspool 450. In one preferred arrangement, theprogrammable drive system 460 is programmable to operate aprogrammable drive 430 and a take upmotor 470 to achieve a desired feed rate of the plurality ofsusceptor coil assemblies 20 from thetensioning section 100 to theimpaling section 300. Preferably, the take upmotor 470 comprises a smart motor such as an induction motor comprising an integral encoder that provides position shaft position feedback to thesystem software 700. In one preferred arrangement, theprogrammable drive system 460 may be operated and controlled by way of acomputing device 725 running thesystem software 700. - The
tensioning section 100, thecollimating section 300, theimpaling section 300, and the take upsection 400 may all be operated by way of thecomputing device 725 wherein thesystem software 700 may be accessible by way of agraphical user interface 750. As previously described, the system software may comprise a G-code logic system software provided by Moog Animatics. Theapparatus 10 comprises a programmable drive system (e.g., a smart motor) that may be operated so as to fabricate a susceptorcoil assembly ribbon 30 comprising a plurality of susceptor coil assemblies (such as the susceptor coil assembly illustrated inFIG. 2 ) that are impaled into a matrix material 320 (e.g., one or more layers of matrix material). -
FIG. 20 illustrates amethod 1000 of fabricating a susceptorcoil assembly ribbon 30 comprising a plurality ofsusceptor coil assemblies 20, such as the susceptor coil assembly illustrated inFIG. 2 . According to one arrangement, the method includes thestep 1010 of pulling a plurality ofsusceptor coil assemblies 20 from atensioning section 100 towards acollimating section 200. Atstep 1020, the method includes the step of utilizing aprogrammable drive 430 to pull the plurality ofsusceptor coil assemblies 20 from thetension section 100 through theimpaling section 300, theprogrammable drive 430 programmable to operate a take upmotor 470. - The method further includes the
step 1030 of maintaining a desired tension in the plurality ofsusceptor coil assemblies 20 as the plurality ofsusceptor coil assemblies 20 are pulled from thetension section 100 and into thecollimating section 200. - The method further includes the
step 1040 of collimating the plurality ofsusceptor coil assemblies 20 as the plurality ofsusceptor coil assemblies 20 are pulled from thetensioning section 100 towards acollimating section 200. The step of collimating may include the step of aligning the plurality ofsusceptor coil assemblies 20. Specifically, the method includes thestep 1050 of utilizing a multi-grooved aligningmember housing 220 comprising a plurality ofgrooves 240 to align the plurality ofsusceptor coil assemblies 20 as the plurality ofsusceptor coil assemblies 20 are pulled from thetensioning section 100 and into theimpaling section 300. - The method further includes the
step 1060 of impaling the plurality ofsusceptor coil assemblies 20 into amatrix material 320 so as to fabricate a susceptorcoil assembly ribbon 30. For example, impaling the plurality ofsusceptor coil assemblies 20 into amatrix material 320 so as to fabricate a susceptorcoil assembly ribbon 30 may comprise impaling the plurality ofsusceptor coil assemblies 20 into at least one layer of thematrix material 320. Thematrix material 320 may be provided by a firstmatrix material source 324. Alternatively, thematrix material 320 may be provided by a firstmatrix material source 324 and a secondmatrix material source 328. - The method may include the optional step of slitting 1070 the susceptor
coil assembly ribbon 30 to a desired width 40. - The method may also include the
optional step 1080 of receiving the susceptorcoil assembly ribbon 30 from theimpaling section 300 by a take upsection 400 comprising a take up spool 420. The method includes thestep 1090 of winding the susceptorcoil assembly ribbon 30 onto the take up spool 420. - The method may also include the
step 1090 of curing the susceptorcoil assembly ribbon 30. -
FIG. 21 is an illustration of a perspective view of anaircraft 1600 that may incorporate one or more composite laminate structures heated by a heating blanket incorporating one of the susceptor coil assembly ribbon embodiments of the present disclosure. - As shown in
FIG. 21 , theaircraft 1600 comprises afuselage 1612, anose 1614, acockpit 1616,wings 1618 operatively coupled to thefuselage 1620, one ormore propulsion units 1620, a tailvertical stabilizer 1622, and one or more tailhorizontal stabilizers 1624. Although theaircraft 1600 shown inFIG. 21 is generally representative of a commercial passenger aircraft, heating blankets comprising one or more susceptor coil assemblies as disclosed herein, may also be employed in other types of aircraft or air vehicles. More specifically, the teachings of the disclosed embodiments may be applied to other passenger aircraft, cargo aircraft, military aircraft, rotorcraft, and other types of aircraft or aerial vehicles, as well as aerospace vehicles, satellites, space launch vehicles, rockets, and other aerospace vehicles. It may also be appreciated that embodiments of structures and methods in accordance with the disclosure may be utilized in other transport vehicles, such as boats and other watercraft, trains, automobiles, trucks, buses, or other suitable transport vehicles heated by susceptor coil assembly based heating blankets as disclosed herein. - Embodiments of the disclosure may find use in a variety of potential applications, particularly in the transportation industry, including for example, aerospace, marine, automotive applications and other application where thermoplastic composite tubular structures may be used. Therefore, referring now to
FIGS. 22 and 23 , embodiments of the disclosure may be used in the context of an aircraft manufacturing andservice method 1630 as shown inFIG. 22 and anaircraft 1650 as shown inFIG. 23 . Aircraft applications of the disclosed embodiments may include, for example, without limitation, the design and fabrication of composite laminates fabricated by way of a releasable support as disclosed herein. - During pre-production,
exemplary method 1630 may include specification anddesign 1632 of theaircraft 1650 andmaterial procurement 1634. As just one example, at this step, this might include the selection of material type of susceptor conductor or conductors may be determined at this step. In addition, during this step, the various heating requirements of a susceptor coil assembly based heating blanket may be determined. For example, during this step, the number of susceptor coil assemblies to be used in a specific heating blanket application may be determined. - During production, component and
subassembly manufacturing 1636 andsystem integration 1638 of theaircraft 1650 takes place. After such a component and subassembly manufacturing step, theaircraft 1650 may go through certification anddelivery 1640 in order to be placed inservice 1642. While in service by a customer, theaircraft 1650 is scheduled for routine maintenance andservice 1644, which may also include modification, reconfiguration, refurbishment, and so on. - Each of the process steps of
method 1650 may be performed or carried out by a system integrator, a third party, and/or an operator (e.g., a customer). For the purposes of this description, a system integrator may include without limitation any number of aircraft manufacturers and major-system subcontractors; a third party may include without limitation any number of vendors, subcontractors, and suppliers; and an operator may be an airline, leasing company, military entity, service organization, and so on. - As shown in
FIG. 23 , theaircraft 1650 produced byexemplary method 1630 may include anairframe 1652 with a plurality of high-level systems 1654 and an interior 1656. Examples of high-level systems 1654 may include one or more of apropulsion system 1658, anelectrical system 1660, ahydraulic system 1662, and anenvironmental system 1664. Any number of other systems may be included. Although an aerospace example is shown, the principles of the disclosure may be applied to other industries, such as the marine and automotive industries. - Systems and methods embodied herein may be employed during any one or more of the stages of the production and
service method 1630. For example, components or subassemblies corresponding to production process may be fabricated or manufactured in a manner similar to components or subassemblies produced while theaircraft 1650 is in service. Also, one or more apparatus embodiments, method embodiments, or a combination thereof may be utilized during theproduction stages aircraft 1650. Similarly, one or more of apparatus embodiments, method embodiments, or a combination thereof may be utilized while theaircraft 1650 is in service, for example and without limitation, to maintenance andservice 1644. - The description of the different advantageous embodiments has been presented for purposes of illustration and description, and is not intended to be exhaustive or limited to the embodiments in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art. Further, different advantageous embodiments may provide different advantages as compared to other advantageous embodiments. The embodiment or embodiments selected are chosen and described in order to best explain the principles of the embodiments, the practical application, and to enable others of ordinary skill in the art to understand the disclosure for various embodiments with various modifications as are suited to the particular use contemplated.
Claims (20)
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